Magnum MLT4150MV User manual

Parts manuals available online! www.m-p-llc.com
POWER PRODUCTS LLC
LIGHT TOWER
MLT4150MV • MLT4200IV
00122
MLT4200IVCAN
OPERATING MANUAL

2
INTRODUCTION
This manual provides information and procedures to safely operate and maintain the Magnum Power Products LLC
unit. For your own safety and protection from physical injury, carefully read, understand, and observe the safety
instructions described in this manual. Keep a copy of this manual with the unit at all times. Additional copies are
available from Magnum Power Products LLC, or can be found at www.m-p-llc.com.The information contained in
this manual was based on machines in production at the time of publication. Magnum Power Products LLC reserves
the right to change any portion of this information without notice.
Read all of the manuals included with the unit. Each manual details specific information regarding items such as
setup, use and service requirements. An engine operator’s manual provides detailed operation and maintenance
procedures for the engine. Additional copies of the engine operator’s manual are available from the engine
manufacturer.
DO NOT MODIFY or use this equipment for any application other than which it was designed for.
Magnum Power Products LLC recommends that a trained and licensed professional perform all electrical wiring and
testing functions. Any wiring should be in compliance with the National Electrical Code (NEC), state and local codes
and Occupational Safety and Health Association (OSHA) guidelines.
MAGNUM POWER PRODUCTS LLC
215 Power Drive • Berlin, WI 54923
U.S.A.
Phone: [phone]
FAX: [phone]
Toll Free: 1-800-926-9768
www.m-p-llc.com
For technical or parts QUESTIONS, please contact the Magnum Power Products LLC Customer
Support or Technical Support team at 1-800-926-9768. Please have your serial number available.
To ORDER SERVICE PARTS, please contact the dealer from which you purchased the unit, or call
Magnum Power Products LLC to locate a dealer in your area.
Engine Make:__________________________________________
Engine Serial Number:___________________________________
Engine Model Number: __________________________________
Generator Make: _______________________________________
Generator Model Number: ________________________________
Generator Serial Number: ________________________________
Unit Model Number:_____________________________________
Unit Serial Number: _____________________________________
WARNING
CALIFORNIA PROPOSITION 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.

3
TABLE OF CONTENTS
Page
INTRODUCTION ................................................................................................................................ 2
SAFETY NOTES ................................................................................................................................ 4
OPERATING SAFETY ....................................................................................................................... 4
ENGINE SAFETY............................................................................................................................... 5
SERVICE SAFETY............................................................................................................................. 6
TOWING SAFETY.............................................................................................................................. 6
REPORTING TRAILER SAFETY DEFECTS ..................................................................................... 7
SAFETY SYMBOL SUMMARY .......................................................................................................... 8
SPECIFICATIONS - MLT4150MV, MLT4200IV ................................................................................. 9
SPECIFICATIONS - MLT4200IVCAN .............................................................................................. 10
UNIT DIMENSIONS ......................................................................................................................... 11
UNIT SERIAL NUMBER LOCATIONS ............................................................................................ 12
COMPONENT LOCATIONS ............................................................................................................ 13
LIGHT TOWER SET UP................................................................................................................... 14
RAISING THE MAST........................................................................................................................ 15
MAIN CONTROL PANEL ................................................................................................................. 16
PRESTART CHECKLIST ................................................................................................................. 17
EMERGENCY STOP SWITCH ........................................................................................................ 17
STARTING THE UNIT...................................................................................................................... 17
AUTOMATIC SHUTDOWN ..............................................................................................................18
LIGHT OPERATION......................................................................................................................... 18
VOLTAGE REGULATION ................................................................................................................ 19
DERATING FOR ALTITUDE ............................................................................................................ 19
WET STACKING .............................................................................................................................. 19
RECEPTACLE PANEL..................................................................................................................... 19
SHUTTING DOWN THE UNIT ......................................................................................................... 20
LOWERING THE MAST................................................................................................................... 20
REMOVING THE LIGHTS FOR TRANSPORTATION ..................................................................... 21
TOWING THE UNIT ......................................................................................................................... 21
LIFTING THE UNIT .......................................................................................................................... 22
GENERAL MAINTENANCE .............................................................................................................23
BASIC MAINTENANCE SCHEDULE - MITSUBISHI ENGINE ........................................................ 24
BASIC MAINTENANCE SCHEDULE - ISUZU ENGINE .................................................................. 25
WINCH USE, OPERATION & MAINTENANCE ............................................................................... 26
JACK MAINTENANCE ..................................................................................................................... 26
TRAILER WHEEL BEARINGS ......................................................................................................... 27
LOWER RADIATOR HOSE HEATER OPTION - USE AND MAINTENANCE ................................. 27
TROUBLESHOOTING THE LIGHTS ............................................................................................... 28
MAST LIGHT CONNECTIONS ........................................................................................................ 29
AC WIRING DIAGRAM .................................................................................................................... 30
AC WIRING DIAGRAM - RECEPTACLE PANEL ............................................................................ 31
AC WIRING DIAGRAM - RECEPTACLE PANEL OPTIONS (1 OF 2) ............................................. 32
AC WIRING DIAGRAM - RECEPTACLE PANEL OPTIONS (2 OF 2) ............................................. 33
DC WIRING DIAGRAM .................................................................................................................... 34
DC WIRING DIAGRAM - ELECTRIC WINCH .................................................................................. 35
DC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT ............................................................... 36
TRAILER LIGHTS WIRING DIAGRAM ............................................................................................ 37
SERVICE LOG ................................................................................................................................. 38

4
SAFETY NOTES
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.
This manual contains DANGERS, WARNINGS, CAUTIONS, NOTICES and NOTES which must be
followed to prevent the possibility of improper service, damage to the equipment, personal injury or death.
The following formatting options will apply when calling the readers attention to the DANGERS, WARN-
INGS, CAUTIONS, NOTICES and NOTES.
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.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
Indicates a hazardous situation which, if not avoided, could result in property or equipment
damage.
Note: Notes contain additional information important to a procedure and will be found within the regular text body
of this manual.
OPERATING SAFETY
Before using the unit be sure to read and understand all of the instructions provided with the unit. This
equipment was designed for specific applications; DO NOT modify or use this equipment for any application
other than which it was designed for. Equipment operated improperly or by untrained personnel can be
dangerous.
Read the operating instructions and familiarize yourself with the location and proper use of all instruments
and controls. Inexperienced operators should receive instruction from someone familiar with the equipment
before being allowed to operate or set up the unit. The following points should be practiced at all times:
• The area immediately surrounding the unit should be dry, clean, and free of debris.
• Position and operate the unit on a firm, level surface.
•NEVER start a unit in need of repair.
•ALWAYS lower the mast when not in use, or if high winds or electrical storms are expected in the area.
• Make certain the unit is well grounded and securely fastened to a good earthen ground. Follow any
local, state or National Electrical Code (NEC) guidelines.
• The mast extends up to 25 ft (7.6 m). ALWAYS make sure the area above the unit is open and clear
of overhead wires and obstructions.
• Keep area around the mast clear of people while raising and lowering the mast.
• Keep all body parts, clothing and other loose items clear of the winch, cables and pulleys during
operation.
• Bulbs become extremely hot during use. Allow them to cool 10-15 minutes before handling.
•NEVER raise or lower the mast while lights are in operation.

5
•ALWAYS extend the outriggers and level the unit before raising the mast. DO NOT retract the outriggers
while the mast is up.
• If for any reason any part of the mast hangs up or the winch cable develops slack while raising or
lowering the mast, STOP immediately and contact an authorized service representative.
•NEVER use the unit if insulation on the electrical cord is cut or worn through.
•NEVER operate the lights without protective lens covers in place or with a lens cover that is cracked
or damaged.
• Only use mild soap and water to clean the lens covers. Other chemicals may have an adverse effect
on the glass.
•NEVER operate a unit while tired, distracted, or under the influence of drugs or alcohol.
ENGINE SAFETY
Internal combustion engines present special hazards during operation and fueling. Failure to follow the
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 was shipped from the factory.
•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
ventilation equipment.
•DO NOT operate the unit on a combustible surface.
•DO NOT fill fuel tank near an open flame, while smoking, or while engine is running. DO NOT fill tank
in an enclosed area with poor ventilation.
•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.
•DO NOT remove engine coolant cap while engine is hot.
•DO NOT operate the unit without a functional exhaust system. Prolonged exposure to sound levels
in excess of 85 dB(A) can cause permanent hearing loss. Wear hearing protection when working
around a running engine.
• 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 or eat holes in clothing. Protective eye wear and clothing are necessary when
working on or around the battery. Always disconnect the negative (-) battery cable from the
corresponding terminal before performing any service on the engine or other components.
• Shut the engine down if any of the following conditions exist during operation:
1. Noticeable change in engine speed.
2. Loss of electrical output.
3. Equipment connected to the generator overheats.
4. Sparking occurs.
5. Engine misfires or there is excessive engine/generator vibration.
6. Protective covers are loose or missing.
7. If the ambient air temperature is above 120°F (49°C).

6
SERVICE SAFETY
This unit uses high voltage circuits capable of causing serious injury or death. Onlyaqualified electrician
should troubleshoot or repair electrical problems occurring in this equipment.
• Before servicing, make sure the Engine Start switch is turned to OFF, circuit breakers are open (off)
and the negative terminal on the battery is disconnected. NEVER perform even routine service (oil/
filter changes, cleaning, etc.) unless all electrical components are shut down.
•NEVER allow water to accumulate around the base of the unit. If water is present, DO NOT service.
•NEVER service electrical components if clothing or skin is wet. If the unit is stored outside, check the
engine and generator for any moisture and dry the unit before use.
•NEVER wash the unit with a power washer or high pressure hose.
• Open the main circuit breaker before disconnecting battery cables.
• Keep all body parts, clothing, and other loose items away from moving parts on the unit.
• Wear heavy leather gloves when handling winch cables. Never let cables slip through bare hands.
• Make sure slings, chains, hooks, ramps, jacks, and other types of lifting devices are attached securely
and have enough weight-bearing capacity to lift or hold the unit safely. Always remain aware of the
position of other people around when lifting the unit.
TOWING SAFETY
Towing a trailer requires care. Both the trailer and vehicle must be in good condition and securely fastened
to each other to reduce the possibility of an accident. Some states require that large trailers be registered
and licensed, contact your local Department of Transportation office to check on license requirements for
your particular unit.
• Check that the hitch and coupling on the towing vehicle are rated equal to, or greater than, the trailer's
Gross Vehicle Weight Rating (GVWR).
• Check tires on trailer for tread wear, inflation, and condition.
•NEVER tow trailer using defective parts. Inspect the hitch and coupling for wear or damage.
• Make sure the trailer hitch and the coupling are compatible. Make sure the coupling is securely fastened
to the vehicle.
• 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.
• Make sure directional and brake lights on the trailer are connected and working properly.
• Check that all lug nuts holding wheels on are tight and none are missing.
• Maximum recommended speed for highway towing is 45 mph (72 km/h). Recommended off-road
towing speed is not to exceed 10 mph (16 km/h) or less, depending on terrain.
• When towing, maintain extra space between vehicles and avoid soft shoulders, curbs and sudden
lane changes. If you have not pulled a trailer before, practice turning, stopping, and backing up in an
area away from heavy traffic.

7
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 immediately
inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Magnum Power Products
LLC.
If NHTSA receives similar complaints, it may open an investigation; and if it finds that a safety defect exists in a group
of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in an individual
problem between you, your dealer, or Magnum Power Products LLC.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-888-327-4236 (TTY:1-800-424-9153),
go to http://www.safercar.gov; or write to:
Administrator
NHTSA
1200 New Jersey Avenue S.E.
Washington, DC 20590
You can also obtain other information about motor vehicle safety from http://www.safercar.gov.

8
SAFETY SYMBOL SUMMARY
This equipment has been supplied with numerous safety and operating decals. These decals provide important
operating instructions and warn of dangers and hazards. Replace any 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 parts manual. Below is
a summary of the intended meanings for the symbols used on the decals.
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.
00198

9
SPECIFICATIONS - MLT4150MV, MLT4200IV
MAGNUM MODEL MLT4150MV MLT4200IV
Engine
Make/Brand................................................................... Mitsubishi......................................Isuzu
Model ............................................................................ S4L2-W461ML..............................4LE1NYGV-03
4LE1NYGV-03E
EPA Tier ........................................................................ 4f...................................................4i
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)
Operating Speed rpm .................................................. 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)
Battery Type - Group Number....................................... 24..................................................24
Battery Voltage (Quantity per Unit) ............................... 12V (1)..........................................12V (1)
Battery Rating ............................................................... 440 CCA .......................................720 CCA
Generator
Make/Brand................................................................... Marathon Electric..........................Marathon Electric
Model ............................................................................ 333CSA3024 ................................334CSA3028
Type, Insulation............................................................. Brushless, F..................................Brushless, F
Generator Set (Engine/Generator)
Output - Standby kW (kVA) .......................................... 15.0 (15.0) .................................... 20.0 (20.0)
Output Voltage V.......................................................... 120/240, single phase................... 120/240, single phase
Output Amperes 120V (240V) A .................................. 125 (63) ........................................ 167 (83)
Frequency Hz ............................................................... 60..................................................60
Power Factor................................................................. 1 (1Ø)............................................1 (1Ø)
Weights
Dry Weight lbs (kg) ....................................................... 2080 (943) ....................................2084 (945)
Operating Weight lbs (kg) ............................................ 2483 (1126)...................................2487(1128)
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
Lighting
Lighting Type................................................................. Metal Halide.................................. Metal Halide
Ballast Type .................................................................. Coil & Core ...................................Coil & Core
Lumens ......................................................................... 440,000.........................................440,000
Coverage acres (m2)................................................... 5 - 7 (20,234 - 28,328) ..................5 - 7 (20,234 - 28,328)
AC Distribution
Circuit Breaker Size ...................................................... 70..................................................100
Voltage Regulation ........................................................ +/-1% ............................................+/-1%
Voltages Available 1Ø ................................................... 120, 240........................................120, 240
Trailer
Number of Axles ........................................................... 1....................................................1
Capacity - Axle Rating lbs (kg) .................................... 3000 (1361) ..................................3000 (1361)
Tire Size in ................................................................... 15..................................................15
Hitch - Standard ............................................................ 2" Ball ...........................................2" Ball
Maximum Tire Pressure psi .......................................... 50..................................................50
Specifications are subject to change without notice.

10
SPECIFICATIONS - MLT4200IVCAN
MAGNUM MODEL MLT4200IVCAN
Engine
Make/Brand..........................................................................................................................Isuzu
Model ...................................................................................................................................4LE1NYGV-03G1
EPA Tier ...............................................................................................................................4i
Type .....................................................................................................................................Diesel, liquid cooled, 4-stroke
Horsepower - prime hp (kW) ..............................................................................................31.5 (23.5)
Horsepower - standby hp (kW) ...........................................................................................34.5 (25.7)
Operating Speed rpm .........................................................................................................1800
Displacement in3(L) ...........................................................................................................134.25 (2.20)
Cylinders - qty ......................................................................................................................4
Fuel Consumption - 100% prime gph (Lph) .......................................................................1.80 (6.81)
Battery Type - Group Number..............................................................................................24
Battery Voltage (Quantity per Unit) ......................................................................................12V (1)
Battery Rating ......................................................................................................................720 CCA
Generator
Make/Brand..........................................................................................................................Marathon Electric
Model ...................................................................................................................................334CSA3028
Type, Insulation....................................................................................................................Brushless, F
Generator Set (Engine/Generator)
Output - Standby kW (kVA) .................................................................................................20.0 (20.0)
Output Voltage V.................................................................................................................120/240, single phase
Output Amperes 120V (240V) A ......................................................................................... 167 (83)
Frequency Hz ......................................................................................................................60
Power Factor........................................................................................................................1 (1Ø)
Weights
Dry Weight lbs (kg) ..............................................................................................................2084 (945)
Operating Weight lbs (kg) ...................................................................................................2487(1128)
Capacities
Fuel Tank Volume gal (L) ....................................................................................................56 (212)
Usable Fuel Volume gal (L) ................................................................................................56 (212)
Coolant (incl. engine) qt (L) ................................................................................................11.6 (11.0)
Oil (incl. filter) qt (L) ............................................................................................................8.6 (8.1)
Maximum Run Time hrs .....................................................................................................31
Lighting
Lighting Type........................................................................................................................Metal Halide
Ballast Type ......................................................................................................................... Coil & Core
Lumens ................................................................................................................................440,000
Coverage acres (m2)..........................................................................................................5 - 7 (20,234 - 28,328)
AC Distribution
Circuit Breaker Size ............................................................................................................. 100
Voltage Regulation ...............................................................................................................+/-1%
Voltages Available 1Ø ..........................................................................................................120, 240
Trailer
Number of Axles ..................................................................................................................1
Capacity - Axle Rating lbs (kg) ...........................................................................................3000 (1361)
Tire Size in ..........................................................................................................................15
Hitch - Standard ...................................................................................................................2" Ball
Maximum Tire Pressure psi .................................................................................................50
Specifications are subject to change without notice.