Magnum MLT 4250 User manual

OPERATING/PARTS MANUAL
MLT 4250

2
INTRODUCTION
Thismanualprovidesinformationandprocedurestosafelyoperateandmaintainthelighttowerandgenerator. For
yourownsafety and 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.
MagnumProductsLLCrecommendsthatatrainedandlicensedprofessionalperformallelectricalwiringandtesting
functions. Any wiring should be in compliance with the United States National Electric Code (NEC), state and local
codesandOccupationalSafetyandHealthAssociation(OSHA)guidelines.
Keep a copy of this manual with the unit at all times. Additional copies are available from Magnum Products LLC, or
can be found at www.m-p-llc.com. An engine operators manual was also supplied with the unit at the time of
shipmentfrom the factory. The manual provides detailedoperation and maintenance procedures for the engine.
Additionalcopies of the engine operators manualareavailablefromthe engine manufacturer.
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
CALIFORNIAPROPOSITION65 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
For technical or parts QUESTIONS, please contact Magnum Products’ Customer Support or
Technical Support team at 920-361-4442. Please have your serial number available.
To ORDER SERVICE PARTS, please contact the dealer from which your purchased the unit,
or call Magnum Products to locate a dealer in your area.
EngineMake:
EngineSerial Number:
EngineModelNumber:
GeneratorMake:
GeneratorModelNumber:
GeneratorSerialNumber:
UnitModelNumber:
UnitSerialNumber:

TABLE OF CONTENTS Page
INTRODUCTION .................................................................................................................2
TABLEOFCONTENTS ......................................................................................................3
SAFETYNOTES................................................................................................................4
OPERATINGSAFETY........................................................................................................4
ENGINESAFETY ..............................................................................................................5
SERVICESAFETY ............................................................................................................5
TOWINGSAFETY..............................................................................................................6
REPORTINGTRAILERSAFETY DEFECTS .......................................................................6
UNITSERIALNUMBERLOCATIONS .................................................................................6
SAFETYSYMBOL SUMMARY..........................................................................................7
SPECIFICATIONS ........................................................................................................ 8 - 9
EXTERIORLOCATIONS ...................................................................................................10
MAINCONTROLPANELCOMPONENTS ........................................................................ 11
MAGNUMDIGITALCONTROLLER(MDC) ................................................................ 12 - 13
GENERATORMONITORING ............................................................................................13
ENGINEMONITORING ............................................................................................ 14 - 15
FINEVOLTAGEADJUSTMENT ....................................................................................... 15
MDCCONTROLLERINFORMATIONDISPLAYS,FUNCTIONSANDRESET....................16
MDCCONTROLLER- GENERATOROPERATIONALSTATUS.........................................16
MDCCONTROLLER-ALARMMANAGEMENT ...............................................................16
MDCCONTROLLERLISTOFPOSSIBLEALARMSWITHDESCRIPTIONS..............17 - 18
MDCCONTROLLER-HISTORY ......................................................................................18
ADJUSTINGTHEDISPLAYBACKLIGHTING....................................................................19
RESETTINGTHE“TIME TOSERVICE” REMINDER.........................................................19
GENERATOROUTPUTCONNECTIONLUGS ..................................................................20
VOLTAGESELECTORSWITCH ......................................................................................21
AUXILIARYOUTLETS ......................................................................................................22
VOLTAGEREGULATION..................................................................................................22
EMERGENCYSTOP SWITCH ........................................................................................ 22
MAINCIRCUITBREAKER................................................................................................23
REMOTESTARTTERMINALBLOCK...............................................................................23
TRANSFERSWITCH ................................................................................................23 - 24
LIGHTTOWERSET-UP ...................................................................................................25
RAISINGTHETOWER.....................................................................................................26
RAISINGTHETOWER WITHOPTIONAL ELECTRICWINCH...........................................27
LIGHTTOWERSTARTUP ...............................................................................................28
PRE-STARTCHECKLIST .................................................................................................28
MANUALSTARTINGOFTHEGENERATOR .............................................................28 - 30
AUTO(REMOTE)STARTINGOFTHEGENERATOR .......................................................30
LIGHTOPERATION..........................................................................................................31
SHUTTINGDOWNTHEGENERATOR .............................................................................31
LOWERING THETOWER ................................................................................................32
LOWERINGTHETOWER WITHOPTIONAL ELECTRICWINCH......................................32
REMOVINGTHELIGHTSFORTRANSPORTATION.........................................................33
TOWINGTHETRAILER ...................................................................................................33
TRAILERWHEEL BEARINGS .........................................................................................33
LIFTINGTHETRAILER.....................................................................................................34
GENERALMAINTENANCE..............................................................................................34
ENGINEMAINTENANCE .................................................................................................35
OPTIONALLOWERRADIATORHOSE HEATER USEAND MAINTENANCE ...................35
DERATINGFORALTITUDE ..............................................................................................36
TROUBLESHOOTINGSHUTDOWNCONDITIONS ...........................................................36
TROUBLESHOOTINGTHELIGHTS .................................................................................37
UNITDECALS...........................................................................................................38 - 41
MANUALWINCHMASTASSEMBLY........................................................................42 - 43
ELECTRICWINCH MASTASSEMBLY......................................................................44 - 45
FRAMEANDCOMPONENTS ...................................................................................46 - 48
GENERATORASSEMBLY ...............................................................................................49
MASTJUNCTIONBOXASSEMBLY-HARD WIREDLIGHTS...........................................50
MASTJUNCTION BOXASSEMBLY-QUICKDISCONNECTLIGHTS...............................51
ENCLOSUREASSEMBLY ........................................................................................52 - 53
AUXILIARYOUTLETPANELASSEMBLY..................................................................54 - 55
AUXILIARYOUTLETPANELOPTIONS .....................................................................56 - 57
LIGHTASSEMBLY ....................................................................................................58 - 59
ENGINECOOLINGASSEMBLY................................................................................60 - 61
ENGINEASSEMBLY ................................................................................................62 - 63
CONTROLPANELASSEMBLY.................................................................................64 - 65
CONTROLBOXASSEMBLY .....................................................................................66 - 67
LUGDOORASSEMBLY ..................................................................................................68
WIRINGDIAGRAMS .................................................................................................69 - 75 3

4
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,personalinjury ordeath.
Thefollowing formattingoptionswill applywhencalling the readersattentionto theDANGERS,WARN-
INGS,CAUTIONS,NOTICESandNOTES.
SAFETY NOTES
NOTICE
Indicatesahazardoussituationwhich,ifnotavoided,
mayresult inpropertyorequipment damage.
Note: Notescontain additionalinformationimportant to aprocedureand will befoundwithin theregular
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.
Inexperiencedoperatorsshouldreceiveinstructionfromsomeonefamiliarwiththeequipmentbeforebeing
allowed to operate or set up the light tower. The following points should be practiced at all times:
•Thearea immediatelysurroundingthelight towershouldbedry, clean,andfreeof debris.
•Positionandoperatethelight 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.
•Makecertain light tower is well grounded and securely fastenedtoagoodearthenground.
•Thetower extends up to 30 ft. (9m). Make sure area above trailer is open and clear of 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,lower or turn mast while unitisoperating!
•Trailermustbeleveledandoutriggersextendedbeforeraisingtower. Outriggersmustremainex-
tendedwhile tower is up.
•Iffor any reason any part of mast hangs up or winch cable develops slack while raising or lowering
tower,STOPimmediately! Contactanauthorizedservicerepresentative.
• NEVER removesafety pin or pull mast locking 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!

5
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.
• DONOT removeenginecoolant cap whileengineis hot.
• DO NOT operate the unit without a functional exhaust system. Prolonged exposure to sound levels in
excessof85 DBA can cause permanent hearing loss. Wear hearingprotectionwhen working around
arunningengine.
•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,burnfleshor eat holes in clothing. Protective eye wear andclothingarenecessary when
working on or around the battery. Always disconnect the NEGATIVE (-) battery cable from the
correspondingterminalbeforeperforminganyserviceontheengineorothercomponents.
• Shuttheenginedownifany of the following conditions exist during operation:
1. Noticeablechange in engine speed.
2. Loss of electrical output.
3. Equipmentconnected to the generatoroverheats.
4. Sparkingoccurs.
5. Enginemisfires or there isexcessiveengine/generatorvibration.
6. Operatingon a combustible surface.
7. Protectivecovers are loose or missing.
8. Ifthe ambient air temperature is above110°F.
ENGINE SAFETY
This unit uses high voltage circuits capable of causing serious injury or death. Only a qualified electrician
shouldtroubleshootorrepairelectricalproblemsoccurringin thisequipment.
•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
theengine and generator foranymoistureand dry the unitbeforeuse.
• NEVER washthe unitwithapower washer orhighpressure hose.
•Openmaincircuitbreaker beforedisconnectingbatterycables.
•Keephands,feet,andlooseclothingawayfrommovingpartsongeneratorandengine.
•Make sure slings, chains, hooks, ramps, jacks, and other types of lifting devices are attached
securelyandhaveenoughweight-bearing capacity to lift or hold the equipment safely. Always
remainawareofthepositionofotherpeoplearoundyouwhenliftingtheequipment.
SERVICE SAFETY

6
Towinga trailer requires care! Both thetrailer and vehicle must be in good condition 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 of Transportation office to check 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).
• Checktires on trailer for tread wear, inflation, and condition.
•Inspectthe hitchandcoupling forwearor damage. DO NOT tow trailerusingdefective 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.
•Makesuredirectionalandbrakelightsonthetrailerareconnectedandworkingproperly.
•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,maintainextraspacebetween vehicles and avoid soft shoulders, curbs and sudden lane
changes. Ifyou have not pulled a trailer before, practice turning, stopping, and backing up in an area
awayfrom heavytraffic.
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-
atelyinformtheNationalHighwayTrafficSafetyAdministration (NHTSA) in addition 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
agroup of vehicles, it may order a recall and remedy campaign. However,NHTSAcannotbecomeinvolvedin
individualproblem between you, your dealer,or Magnum ProductsLLC.
To contactNHTSA, youmay either call theAuto Safety Hotline toll-free at 1-888-327-4236or by fax at: (202)-366-
7882. Additionalcontactinformationcanbefound at: www.nhtsa.dot.gov.
UNIT SERIAL NUMBER LOCATIONS
Refer to the locations illustrated below to find the unit ID
tag,and trailer ID tagon your unit. Important information,
such as the unit serial number, model number and
VehicleIdentificationNumber(V.I.N.)for your trailer are
foundonthese tags. Record the information from these
tags, so it is available if the tags are lost or damaged.
Whenordering parts or requesting technical service
information, you may be asked to specify this informa-
tion.
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. /CEVEHICULEESTCONFORMEATOUTES 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/TYPE DE VEHICULE:
SerialNumber
kg lbs
rpm hz amb. temp.
V
A
Model
RATING: CONT. STAND BY
3Phase 1Phase
KVA
LR114630-1
FORELECTRICAL
EQUIPMENTONLY.
POURMATERIAL
ELECTRIQUESEULEMENT.
MADEINUSAPRODUCTS LLC
215PowerDrive
Berlin,WI54923
1-800-926-9768
TM
Mfg.Code
V
A
KW
®
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
Located on inside
of panel.

SAFETY SYMBOL SUMMARY
Thisequipmenthasbeensuppliedwithnumeroussafetyandoperatingdecals. Thesedecalsprovideimportant
operatinginstructions and warnofdangersand hazards. Replace anymissingorhard-to-read decals andusecare
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.
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.
7

8
SPECIFICATIONS
Readthismanual carefully before attempting to use this lighttower. The potential forpropertydamage, 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 4250
Engine
Make/Brand ........................................................ Isuzu
Model.................................................................. 4LE1-NYGV-01
Type .................................................................... Diesel,liquid cooled, 4-stroke
Horsepower-primehp (kW) ............................... 31.5 (23.5)
Horsepower-standby hp (kW) ........................... 34.5(25.7)
OperatingSpeedrpm ......................................... 1800
Displacement in3(L) ........................................... 134.25(2.20)
Cylinders - qty .................................................... 4
Fuel Consumption - 100% prime gph (Lph) ....... 1.80(6.81)
BatteryType- Group Number ............................. 24
Battery Voltage (Quantity per Unit) ..................... 12V(1)
BatteryRating..................................................... 720CCA
Generator
Make/Brand ........................................................ MarathonElectric
Model.................................................................. 282NSL1505
Type, Insulation................................................... Brushless, H
Generator Set (Engine/Generator)
3Ø - Standby kW (kVA) ...................................... 20(25)
Amps - 3Ø Standby - 480 (208V) A..................... 30(69)
3Ø - Prime kW (kVA) .......................................... 18(23)
Amps - 3Ø Prime - 480 (208V) A ........................ 28(64)
1Ø - Standby - kW (kVA) .................................... 16.0(16.0)
Amps - 1Ø Standby - 240V A.............................. 67
1Ø - Prime - kW (kVA)........................................ 15.0 (15.0)
Amps - 1Ø Prime - 240V A................................. 63
FrequencyHz ..................................................... 60
PowerFactor ...................................................... 1 (1Ø), 0.8 (3Ø)
Dimensions
Length w/ mast stowed in (m) ............................ 170(4.32)
Width in (m) ....................................................... 63 (1.60)
Width w/ outriggers extended in (m) ................... 140(3.56)
Height w/ mast stowed in (m)............................. 70 (1.78)
Maximum height of tower ft (m) .......................... 30 (9.14)
Weights
DryWeightlbs (kg)............................................. 2158 (979)
OperatingWeight lbs (kg) ................................... 2556(1159)
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

9
SPECIFICATIONS
Readthismanual carefully before attempting to use this lighttower. The potential forpropertydamage, 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.
Lighting
LightingType....................................................... Metal Halide
BallastType........................................................ Coil & Core
Lumens ............................................................... 440,000
Coverageacres (m2)........................................... 5 - 7 (20,234 - 28,328)
ACDistribution
Circuit Breaker Size............................................ 90
VoltageSelection ................................................ 3 Position Switch (lockable)
VoltageRegulation .............................................. +/-1%
VoltagesAvailable1Ø ......................................... 120, 139, 208, 220, 240, 277
VoltagesAvailable3Ø ......................................... 208,220, 440, 480
Trailer
NumberofAxles ................................................. 1
Capacity -Axle Rating lbs (kg) ........................... 3000(1361)
Tire Size in ......................................................... 15
Hitch -Standard .................................................. 2" Ball
MaximumTirePressurepsi ................................ 50

1
2
3
4
5
6
1. FUEL FILLER LOCATION (under door): UsecleanDIESELFUELONLY.
2. RADIATORACCESS PANEL: Removethis panelfor engine coolant service.
3. CONTROL PANEL LOCATION (under door): Engine/generatorcontrolsandallcircuitbreakers.
4. EMERGENCY STOP SWITCH: Foremergency shutdown;stopsengine and tripsmain circuit breaker.
5. EQUIPMENT OUTLETS: Circuitbreakerprotected outlets; 20, 30 and/or 50 ampratings.
6. GROUND STUDS (2): Forgroundinggeneratorandequipmentconnectedtotheequipmentoutlets.
EXTERIOR LOCATIONS
10