Magnum MLT4150 User manual

NIGHTBUSTER LIGHT TOWER
MLT4150 • MLT4200
OPERATING/PARTS MANUAL
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2
INTRODUCTION
This manual provides information and procedures to safely operate and maintain the light tower and generator. For
your own safety and protection from physical injury, 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.
Magnum Products LLC recommends that a trained and licensed professional perform all electrical wiring and testing
functions. Any wiring should be in compliance with the United States National Electric Code (NEC), state and local
codes and Occupational Safety and Health Association (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
provides detailed operation and maintenance procedures for the engine.
Engine Make:
Engine Serial Number:
Engine Model Number:
Generator Make:
Generator Model Number:
Generator Serial Number:
Unit Model Number:
Unit Serial Number:
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
2
WHEN CALLING FOR PARTS OR TECHNICAL SERVICE INFORMATION,
PLEASE HAVE YOUR UNIT MODEL NUMBER AND SERIAL NUMBER READY.
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
TABLE OF CONTENTS ...................................................................................................................3
SAFETY NOTES .............................................................................................................................4
OPERATING SAFETY ..................................................................................................................... 4
ENGINE SAFETY ...........................................................................................................................5
SERVICE SAFETY .........................................................................................................................5
TOWING SAFETY ..........................................................................................................................6
REPORTING TRAILER SAFETY DEFECTS ....................................................................................6
UNIT SERIAL NUMBER LOCATIONS .............................................................................................. 6
SAFETY SYMBOL SUMMARY .......................................................................................................7
SPECIFICATIONS ...........................................................................................................................8
LIGHT TOWER SET UP ..................................................................................................................9
RAISING THE TOWER .......................................................................................................... 10 - 11
MAIN CONTROL PANEL ............................................................................................................... 12
ENGINE STARTING AND OPERATION ......................................................................................... 13
AUTOMATIC SHUTDOWN ............................................................................................................ 13
LIGHT OPERATION ....................................................................................................................... 14
AUXILIARY OUTLETS ................................................................................................................... 14
DERATING FOR ALTITUDE .......................................................................................................... 15
VOLTAGE REGULATION ............................................................................................................... 15
SHUTTING DOWN ........................................................................................................................ 15
LOWERING THE TOWER ...................................................................................................... 15 - 16
REMOVING THE LIGHTS FOR TRANSPORTATION ...................................................................... 16
TOWING THE TRAILER ................................................................................................................ 16
LIFTING THE TRAILER .................................................................................................................. 17
DAILY INSPECTION ...................................................................................................................... 17
TROUBLESHOOTING THE LIGHTS .............................................................................................. 18
ENGINE MAINTENANCE .............................................................................................................. 19
OPTIONAL LOWER RADIATOR HOSE HEATER USE AND MAINTENANCE ................................ 19
UNIT DECALS ........................................................................................................................ 20 - 23
MANUAL WINCH MAST ASSEMBLY ..................................................................................... 24 - 25
ELECTRIC WINCH MAST ASSEMBLY .................................................................................. 26 - 27
AUXILIARY OUTLET PANELASSEMBLY .............................................................................. 28 - 29
AUXILIARY OUTLET PANEL OPTIONS .................................................................................. 30 - 31
ENCLOSURE ASSEMBLY ..................................................................................................... 32 - 33
FRAME AND COMPONENTS ................................................................................................ 34 - 36
ENGINE COOLING ASSEMBLY .................................................................................................... 37
ENGINE ASSEMBLY MITSUBISHI- MLT4150 ......................................................................... 38 - 39
ENGINE ASSEMBLY ISUZU - MLT4200 ................................................................................. 40 - 41
CONTROL PANELASSEMBLY .............................................................................................. 42 - 43
OVAL LIGHT ASSEMBLY ...................................................................................................... 44 - 45
RECTANGULAR LIGHT ASSEMBLY ...................................................................................... 46 - 47
METAL HALIDE BALLAST BOX ASSEMBLY ................................................................................ 48
HIGH PRESSURE SODIUM BALLAST BOX ASSEMBLY .............................................................. 49
MAST JUNCTION BOXASSEMBLY, HARD WIRED LIGHTS ......................................................... 50
MAST JUNCTION BOXASSEMBLY, QUICK DISCONNECT LIGHTS ............................................. 51
GENERATOR ASSEMBLY MLT4150 ............................................................................................. 52
GENERATOR ASSEMBLY MLT4200 ............................................................................................. 53
WIRING DIAGRAMS .............................................................................................................. 54 - 62
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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.
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.
SAFETY NOTES
NOTICE
Indicates a hazardous situation which, if not avoided,
may 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.
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, 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
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 light tower. The following points should be practiced at all
times:
•The area immediately surrounding the light tower should be dry, clean, and free of debris.
•Position and operate the light tower on a firm, level surface.
• NEVER start a unit in need of repair.
•Lower tower when not in use, or if high winds or electrical storms are expected in the area.
•Make certain light tower is well grounded and securely fastened to a good earthen ground.
•The tower extends up to 30 ft. (9 m). Make sure area above trailer is open and clear of overhead wires
and obstructions.
•Bulbs become extremely hot in use! Allow bulb and light fixture to cool 10-15 minutes before handling.
•Keep area behind trailer clear of people while raising and lowering mast!
• NEVER raise, lower or turn mast while unit is operating!
•Trailer must be leveled and outriggers extended before raising tower. Outriggers must remain extended
while tower is up.
•If for any reason any part of mast hangs up or winch cable develops slack while raising or lowering
tower, STOP immediately! Contact an authorized service representative.
• NEVER remove safety pin or pull mast locking pin while tower is up!
• NEVER use tower if insulation on electrical cord is cut or worn through.
• NEVER operate lights without protective lens cover in place or with a lens cover that is cracked or
damaged!
4
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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 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. Operating on a combustible surface.
7. Protective covers are loose or missing.
8. If the ambient air temperature is above 110° F.
ENGINE SAFETY
SERVICE SAFETY
This unit uses high voltage circuits capable of causing serious injury or death. Only a qualified electrician
should troubleshoot or repair electrical problems occurring in this equipment.
•Before servicing the light tower, 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 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
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 main circuit breaker before disconnecting battery cables.
•Keep hands, feet, and loose clothing away from moving parts on generator and engine.
•Replace all guards and safety devices immediately after servicing.
•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 equipment safely. Always
remain aware of the position of other people around you when lifting the equipment.
5
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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. /CEVEHICULEESTCONFORME A 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.
MADEINUSAPRODUCTS LLC
215PowerDrive
Berlin,WI54923
1-800-926-9768
TM
Mfg.Code
V
A
KW
®
Unit ID TagV.I.N. Tag
6
Towing a trailer requires care! Both the trailer 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
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.
•Inspect the hitch and coupling for wear or damage. DO NOT tow trailer using defective parts!
•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 that none are missing.
•Maximum recommended speed for highway towing is 45 mph. Recommended off-road towing speed
is not to exceed 10 mph 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.
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.
TOWING SAFETY
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-
ately inform the National Highway Traffic Safety Administration (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
a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in
individual problems between you, your dealer, or Magnum Products LLC.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-888-327-4236 or by fax at: (202)-366-
7882. Additional contact information can 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
Identification Number (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 requesting technical service information,
you may be asked to specify this information.
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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 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.
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SPECIFICATIONS
Read this manual carefully before attempting to use this generator. The potential for property 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.
MAGNUM MODEL MLT4150 MLT4200
Engine
Make/Brand, Model ................................................ Mitsubishi S4L2-W461ML ................. Isuzu 4LE1-PV05
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 24 ............................................ Group 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)
Dimensions
Length w/ mast stowed in (m) .................................. 170 (4.32) ........................................... 170 (4.32)
Width in (m) .............................................................. 63 (1.60) ............................................. 63 (1.60)
Width w/ outriggers extended in (m) ......................... 140 (3.56) ........................................... 140 (3.56)
Height w/ mast stowed in (m) .................................. 70 (1.78) ............................................. 70 (1.78)
Maximum height of tower ft (m) ................................ 30 (9.14) ............................................. 30 (9.14)
Weights
Dry Weight lbs (kg) ................................................ 2015 (914) .......................................... 2122 (963)
Operating Weight lbs (kg) ..................................... 2413 (1095) ........................................ 2520 (1143)
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, Ballast Type ....................................... Metal Halide, Coil & Core .................. Metal Halide, 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
Voltages Available 3Ø ............................................ N/A ..................................................... N/A
Trailer
Number of Axles ..................................................... 1 .......................................................... 1
Capacity - Axle Rating lbs (kg) ............................. 2500 (1134) ........................................ 2500 (1134)
Tire Size in ............................................................. 15 ........................................................ 15
Hitch - Standard...................................................... 2" Ball ................................................. 2" Ball
Maximum Tire Pressure psi .................................. 50 ........................................................ 50
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H
F
A
GE
D
C
B
D
E
LIGHT TOWER SET UP
1. For maximum light coverage locate tower at ground level or in a spot higher than the area being illuminated 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).
Turn the jack handle clockwise to raise the trailer tongue off of the towing vehicle.
4. Connect a good earthen ground to the grounding stud on the frame of the trailer near the trailer tongue (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 nuts on the light fixture brackets (H) and aiming the lamps 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 C
DETAIL D
DETAIL G
DETAIL H
9
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