Magnum MLT5060 User manual

LIGHT TOWER
MLT5060 • MLT5080
OPERATING/PARTSMANUAL

2
Thismanualprovidesinformationandprocedurestosafelyoperateandmaintaintheengineandgenerator. Foryour
ownsafetyand protection from physical injury, carefully read, understand,andobservethesafetyinstructions
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.
MagnumProductsLLCrecommendsthat atrainedand licensedprofessionalperform allelectricalwiring andtesting
functions. Any wiring should be in compliance with the United States National Electric Code (NEC), state and local
codesand OccupationalSafety andHealthAssociation(OSHA) guidelines.
Keep a copy of this manual with the unit at all times. Additional copies are available from Magnum Products LLC.
An engine operators manual was also supplied with the unit at the time of shipment from the factory. The manual
providesdetailedoperation and maintenance procedures for the engine. Additional copies of the engineoperators
manualareavailable from theenginemanufacturer.
MAGNUM 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
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.
WARNING
Engine Make:
Engine Serial Number:
Engine Model Number:
Generator Make:
Generator Model Number:
Generator Serial Number:
Unit Model Number:
Unit Serial Number:
When calling for Parts or Technical Service information,
please have your unit model number and serial number ready.

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TABLE OF CONTENTS
Page
INTRODUCTION ..............................................................................................................................2
TABLEOFCONTENTS ...................................................................................................................3
SAFETYNOTES.............................................................................................................................4
OPERATINGSAFETY.....................................................................................................................4
ENGINESAFETY ...........................................................................................................................5
SERVICESAFETY .........................................................................................................................5
TOWINGSAFETY ..........................................................................................................................6
UNITSERIALNUMBERLOCATIONS ..............................................................................................6
SAFETYSYMBOL SUMMARY.......................................................................................................7
SPECIFICATIONS ....................................................................................................................8 - 11
LIGHTTOWERSET UP ................................................................................................................12
RAISINGTHE TOWER.......................................................................................................... 12 - 14
MAINCONTROLPANELCOMPONENTS .....................................................................................15
ENGINESTARTINGANDOPERATION .........................................................................................16
AUTOMATICSHUTDOWN ............................................................................................................16
LIGHTOPERATION.......................................................................................................................17
AUXILIARYOUTLETS ...................................................................................................................17
VOLTAGEREGULATION(OPTIONAL) ..........................................................................................17
DERATINGFORALTITUDE ...........................................................................................................18
SHUTTINGDOWN ........................................................................................................................18
LOWERINGTHE TOWER......................................................................................................18 - 19
TOWINGTHETRAILER ................................................................................................................19
LIFTINGTHETRAILER..................................................................................................................20
DAILYINSPECTION......................................................................................................................20
TRAILERWHEELBEARINGS ......................................................................................................21
ENGINEMAINTENANCE ..............................................................................................................22
OPTIONALLOWERRADIATORHOSEHEATERUSEANDMAINTENANCE................................23
TROUBLESHOOTINGTHELIGHTS ..............................................................................................23
MASTLIGHT CONNECTIONS .......................................................................................................24
UNITDECALS........................................................................................................................24 - 28
GENERATORASSEMBLY6 kW...................................................................................................29
GENERATORASSEMBLY8 kW...................................................................................................30
GENERATORASSEMBLY8 kW WITH VOLTAGE REGULATION .................................................31
MANUALWINCH MASTASSEMBLY.....................................................................................32 - 33
ELECTRICWINCHMASTASSEMBLY ..................................................................................34 - 35
ENCLOSUREASSEMBLY .....................................................................................................36 - 37
FRAMEASSEMBLY ..............................................................................................................38 - 40
MASTJUNCTIONBOXASSEMBLY,QUICKDISCONNECTLIGHTS .............................................41
MASTJUNCTIONBOXASSEMBLY,HARDWIREDLIGHTS .........................................................42
MASTJUNCTIONBOXASSEMBLY,6LIGHTQUICKDISCONNECT.............................................43
MITSUBISHIENGINE.............................................................................................................44 - 45
KUBOTAENGINE ..................................................................................................................46 - 47
CONTROLBOXAND PANELASSEMBLY..............................................................................48 - 49
LIGHTASSEMBLY.................................................................................................................50 - 51
METALHALIDEBALLASTBOXASSEMBLY ................................................................................52
HIGHPRESSURESODIUMBALLASTBOXASSEMBLY..............................................................53
WIRINGDIAGRAMS ..............................................................................................................51 - 59

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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,damage totheequipment,personalinjuryordeath.
Thefollowingformatting options willapplywhencallingthe readersattentiontotheDANGERS, WARN-
INGS,CAUTIONS,NOTICESandNOTES.
SAFETY NOTES
NOTICE
Indicatesa hazardoussituationwhich,ifnotavoided,
mayresultin property orequipmentdamage.
Note: Notescontainadditional information importanttoaprocedureand will befoundwithintheregular
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
designedforspecificapplications;DONOTmodifyorusethisequipmentforanyapplicationotherthanwhich
itwasdesignedfor. Equipmentoperatedimproperlyorbyuntrainedpersonnelcanbedangerous! Readthe
operatinginstructionsandfamiliarizeyourselfwiththelocationandproperuseofallinstrumentsandcontrols.
Inexperiencedoperatorsshouldreceiveinstructionfromsomeone familiarwiththeequipmentbeforebeing
allowed to operate or set up the light tower. The following points should be practiced at all times:
•Theareaimmediately surrounding thelighttowershouldbedry, clean, andfreeofdebris.
•Positionandoperatethe light tower on a firm, level surface.
• NEVER startaunit in need of repair.
•Lower tower when not in use, or if high winds or electrical storms are expected in the area.
•Makecertainlighttoweriswellgroundedandsecurelyfastenedto a good earthen ground.
•Thetowerextendsupto30ft.(9m). Makesureareaabovetrailerisopenandclearof overhead wires
andobstructions.
•Bulbs become extremely hot in use! Allow bulb and light fixture to cool 10-15 minutes before han-
dling.
•Keepareabehindtrailerclearofpeoplewhileraisingandloweringmast!
• NEVER raise,lowerorturnmastwhile unit is operating!
•Trailermustbeleveledandoutriggersextendedbeforeraisingtower. Outriggersmustremainex-
tendedwhile tower is up.
•Iffor any reason anypart of mast hangsup or winch cabledevelops slack while raisingor lowering
tower,STOPimmediately! Contactanauthorizedservicerepresentative.
• NEVER removesafety pin or pull mastlocking pin while tower isup!
• NEVER use tower if insulation on electrical cord is cut or worn through.
• NEVER operatelights without protective lens cover in place or with alens 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 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
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.
• DONOTremove engine coolantcapwhileengineis hot.
•Keep area around exhaust pipes and air ducts free of debris to reduce the chance of an accidental
fire.
•Prolonged exposure to sound levels in excess of 85 DBA can cause permanent hearing loss. Wear
hearing protection when working around a running engine. DO NOT operate the unit without a
functionalexhaustsystem.
•Batteries contain sulfuric acid which can cause severe injury or death. Sulfuric acid can cause eye
damage,burnflesh or eat holes in clothing. Protective eyewearandclothing are necessary when
working on or around the battery. Always disconnect the NEGATIVE (-) battery cable from the
correspondingterminalbeforeperforminganyserviceontheengineorothercomponents.
• Shuttheenginedownif any of the following conditions exist during operation:
1. Noticeablechangeinenginespeed.
2. Loss of electrical output.
3. Equipmentconnectedtothe generator overheats.
4. Sparkingoccurs.
5. Enginemisfiresorthere is excessive engine/generator vibration.
6. Operatingonacombustiblesurface.
7. Protectivecoversarelooseormissing.
8. Iftheambientairtemperatureisabove110°F.
ENGINE SAFETY
This unit uses high voltage circuits capable of causing serious injury or death. Only a qualified electrician
shouldtroubleshoot orrepairelectricalproblemsoccurringinthis equipment.
•Before servicing light tower, make sure the engine start switch is turned to OFF, circuit breakers are
open(off)andthenegativeterminalonthebatteryisdisconnected.NEVERperformevenroutine
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
theengineandgeneratorfor any moisture and drytheunitbeforeuse.
• NEVER washtheunitwith a powerwasherorhighpressure hose.
•Openmaincircuitbreakerbeforedisconnectingbatterycables.
•Keephands,feet,and looseclothingawayfrommovingpartsongeneratorandengine.
•Make sure slings, chains, hooks, ramps, jacks, and other types of lifting devices are attached
securelyandhaveenough weight-bearing capacity to lift or hold the equipmentsafely. Always
remainawareofthepositionofotherpeoplearoundyouwhenliftingtheequipment.
SERVICE SAFETY

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MANUFACTURED BY/FABRIQUE PAR:
GVWR/PNBV:
DATE OF MFG:
COLD INFL. PRESS./PRESS.
GAWR/PNBE TIRE/PNEU RIM/JANTE KPA(PSI/LPC)
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:
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
®
Unit ID Tag
V.I.N. Tag
Towinga trailer requires care! Both thetrailer and vehicle must bein good condition and securelyfas-
tened to each other to reduce the possibility of an accident. Also, some states require that large trailers
beregistered and licensed. Contact your localDepartment of Transportation office tocheck on license
requirementsforyourparticularunit.
•Check that the hitch and coupling on the towing vehicle are rated equal to, or greater than, the trailer's
"grossvehicleweightrating"(GVWR).
• Checktiresontrailerfortreadwear,inflation,andcondition.
•Inspectthehitch andcouplingforwearor damage. DO NOT towtrailerusing defectiveparts!
•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.
•Makesuredirectionalandbrakelightson the trailer are connected and working properly.
•Check that all lug nuts holding wheels on are tight and that none are missing.
•Maximumrecommendedspeedforhighwaytowingis45m.p.h. Recommendedoff-roadtowingspeed
is not to exceed 10 m.p.h. or less depending on terrain.
Whentowing,maintainextra space between vehicles and avoid soft shoulders, curbs andsuddenlane
changes. Ifyou have not pulleda trailer before, practiceturning, stopping, and backingup in an area
awayfromheavy traffic.
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-
atelyinformtheNational HighwayTrafficSafetyAdministration(NHTSA)inaddition to notifying Magnum Products
LLC. If NHTSA receives similar complaints, it may open an investigation; and if it finds that a safety defect exists in
agroupofvehicles,itmayorderarecallandremedycampaign. However, NHTSAcannot become involved in
individualproblembetweenyou,yourdealer, or Magnum ProductsLLC.
To contactNHTSA,youmay either call theAutoSafety Hotline toll-free at 1-888-327-4236 orbyfax at: (202)-366-
7882. Additionalcontactinformation can be found at: www.nhtsa.dot.gov.
UNIT SERIAL NUMBER LOCATIONS
Refer to the locations illustrated to find the unit ID
tag, and trailer ID tag on your unit. Important
information,such as the unit serial number, model
numberandVehicleIdentificationNumber(V.I.N.)for
your trailer are found on these tags. Record the
information from these tags, so it is available if the
tags are lost or damaged. When ordering parts or
requestingtechnicalserviceinformation,youmay be
asked to specify this information.

SAFETY SYMBOL SUMMARY
Thisequipmenthasbeensuppliedwithnumeroussafetyandoperatingdecals. Thesedecalsprovideimportant
operatinginstructionsandwarn of dangers andhazards. Replaceanymissingorhard-to-readdecals 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
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.

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SPECIFICATIONS
Readthismanual carefully before attempting to use thislighttower. The potentialforproperty 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 5060
Engine
Make/Brand ........................................................ MITSUBISHI .............................KUBOTA
Model.................................................................. L3E-W461ML (start S#081485).......D905-E3BG
Type .................................................................... Diesel, liquid cooled, 4-stroke....Diesel, liquid cooled, 4-stroke
Horsepower-prime hp (kW) ............................... 10.5(7.8) ...................................10.5(7.8)
Horsepower - standby hp (kW) ........................... 12.2(9.1) ...................................11.9(8.9)
OperatingSpeed rpm ......................................... 1800 ..........................................1800
Displacementin3(L) ........................................... 57.97 (0.95) ...............................54.92(.90)
Cylinders - qty .................................................... 3 ................................................3
Fuel Consumption - 100% prime gph (Lph) ....... 0.52(1.97) .................................0.50(1.89)
BatteryType - Group Number ............................. 24 ..............................................24
BatteryVoltage(Quantity per Unit) ..................... 12V (1).......................................12V(1)
BatteryRating..................................................... 440CCA ....................................440CCA
Generator
Make/Brand ........................................................ MarathonElectric ......................Marathon Electric
Model.................................................................. 201CSA5411..............................201CSA5411
Type, Insulation................................................... Brushless, F ..............................Brushless, F
Generator Set (Engine/Generator)
OutputkW (kVA)................................................. 6.0(6.0) .....................................6.0(6.0)
Output Voltage V................................................ 120/240, single phase................120/240,singlephase
OutputAmperes 120V (240V) A .......................... 50(25) .......................................50(25)
FrequencyHz ..................................................... 60 ..............................................60
PowerFactor ...................................................... 1(1Ø) ........................................1(1Ø)
Weights
DryWeightlbs (kg)............................................. 1771(803) .................................1816(824)
OperatingWeightlbs (kg) ................................... 1920(871) .................................1965(891)
Capacities
Fuel Tank Volume gal (L) ................................... 30(114)......................................30(114)
Usable Fuel Volume gal (L) ................................ 30(114)......................................30(114)
Coolant(incl.engine) qt (L)................................. 4.5 (4.3).....................................4.8(4.5)
Oil (incl. filter) qt (L)............................................ 3.8 (3.6) .....................................5.4 (5.1)
MaximumRunTimehrs...................................... 58 ..............................................60
ACDistribution
Circuit Breaker Size............................................ 30 ..............................................30
VoltageRegulation .............................................. Capacitor+/-6%.........................Capacitor+/-6%
VoltagesAvailable1Ø ......................................... 120,240.....................................120,240

9
SPECIFICATIONS
Readthismanual carefully before attempting to use thislighttower. The potentialforproperty 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 5060
Lighting
LightingType....................................................... MetalHalide
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)
Maximum height of tower ft (m) .......................... 30 (9.14)
Trailer
NumberofAxles ................................................. 1
Capacity-Axle Ratinglbs (kg) ........................... 3500(1588)
Tire Size in ......................................................... 15
Hitch -Standard .................................................. 2" Ball
MaximumTirePressurepsi ................................ 50
SPECIFICATIONSARE SUBJECTTOCHANGEWITHOUTNOTICE.

10
SPECIFICATIONS
Readthismanual carefully before attempting to use thislighttower. The potentialforproperty 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 5080
Engine
Make/Brand ........................................................ MITSUBISHI
Model.................................................................. L3E-W461ML
Type .................................................................... Diesel, liquid cooled, 4-stroke
Horsepower-prime hp (kW) ............................... 10.5(7.8)
Horsepower - standby hp (kW) ........................... 12.2(9.1)
OperatingSpeed rpm ......................................... 1800
Displacement in3(L) ........................................... 57.97(0.95)
Cylinders - qty .................................................... 3
Fuel Consumption - 100% prime gph (Lph) ....... 0.63(2.38)
BatteryType - Group Number ............................. 24
BatteryVoltage(Quantity per Unit) ..................... 12V (1)
BatteryRating..................................................... 440CCA
Generator
Make/Brand ........................................................ MarathonElectric
Model.................................................................. 332CSA5211
Type, Insulation................................................... Brushless, F
Generator Set (Engine/Generator)
OutputkW (kVA)................................................. 7.3(7.3)
Output Voltage V................................................ 120/240, single phase
OutputAmperes 120V (240V) A .......................... 61(30)
FrequencyHz ..................................................... 60
PowerFactor ...................................................... 1(1Ø)
Weights
DryWeightlbs (kg)............................................. 1791(812)
OperatingWeightlbs (kg) ................................... 1940(880)
Capacities
Fuel Tank Volume gal (L) ................................... 30(114)
Usable Fuel Volume gal (L) ................................ 30(114)
Coolant (incl. engine) qt (L)................................. 4.5(4.3)
Oil (incl. filter) qt (L)............................................ 3.8 (3.6)
Maximum Run Time hrs...................................... 48
ACDistribution
Circuit Breaker Size............................................ 40
VoltageRegulation .............................................. Capacitor+/-6%
VoltagesAvailable1Ø ......................................... 120,240