Masalta ML42 User manual

WARNING
!
R
INSTRUCTION MANUAL
LIGHT TOWER
ML42/ML44

1
Table of Contents
1. SAFETY INFORMATION………………………………………………………….…………………………………2
1.1 Safety Precautions ……………………………………………………………………………………….……………2
1.2 Operating Safety…………………………………………………………………………………………………………3
1.3 Operator Safety while using Internal Combustion Engines…………………………………5
1.4 abel locations……………………………………………………………………..………………………….………6
1.5 Safety and Operating abels……………………………………………………………………….…………7
1.6 Service Safety……………………………………………………………………………………………….…………9
2. OPERATION…………………………………………………………………………………………………………………10
2.1 Preparing the Machine for First Use…………………………………………………..……………………10
2.2 ocating ight Tower …………………………………………………………………………………………………10
2.3 eveling Machine ……………………………………………………………………………………..……….………11
2.3.1 Operation of the outriggers…………………………………………………………………..……….………11
2.3.2 Operation of brake …………………………………….………………………………………………..…………12
2.4 Install the light…………………………………………….………………………………………………………………13
2.5 Adjusting the lighting angle…………………………………….…………………………………………………15
2.6 Control Panel …………………………………………………………………….………………………………………16
2.7 Raising the Tower (Manual Winch) ………………………………….………………………………..……16
2.8 owering the Tower (Manual Winch) ……………………………….…………………………………..…17
2.9 Manually Starting the Machine………………………………………….……………..………………………17
2.10 Stopping the Machine……………………………………………………….…………….…………….…………18
2.11 Restart the light on…………………………………………………………….…………….………………………18
2.12 Transportation………………………………………………………………..….….…………………………………18
2.13 Storage………………………………………………………………………………….………….………………………19
3. MAITENANCE………………………………………………………………………….………….………………………20
3.1 Periodic Maintenance Schedule ………………………………………….………….………………………20
3.2 Installing / Removing ight Fixtures ……….…………………………….…………………………………21
3.3 Replacing / Removing amps ………………….…………………………….………..………………………21
3.4 Checking Engine Coolant………………………….…………………………...………..………………………22
3.5 Cleaning Air Filter Element………………………….………………………...…………………………………22
3.6 Changing Engine Oil……………………………………………………………….………..………………………23
3.7 Maintaining the Fuel/Water Separator………….………………………….………………………………23
3.8 Troubleshooting……………………………………………………………..………….….…..………………………25
4. TECHNICAL DATA ……………………………………………………………………….……………………………26
. WARRANTY …………………………………………………………………………………..……………………………27
6 MAINTENANCE RECORD ………….………………………………………………….………………….………28
7 EC DECLARATION ………….………………………………………………………………..……………………….29

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1. SAFETY INFORMATION
1.1 Safety Precautions
Before operating the machine, read both the manual and the engine manual
carefully to become familiar with the location and proper use of all controls. Do not
allow untrained or unauthorized personnel, especially children, to operate this
machine. Use only the parts authorized by the factory for service.
This manual contains DANGER, WARNING, CAUTION callouts which must be
followed to reduce the possibility of personal injury, damage to the equipment, or
improper service.
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.
DANGER indicates a hazardous procedure which, if not
avoided, will result in serious or mortal injury.
WARNING indicates a danger or hazardous procedure
which, if not avoided, could result in serious or mortal
injury.
CAUTION indicates a danger or hazardous procedure
which, if not avoided, could result in damage to
machinery or moderate injury.
CAUTION
DANGER
SAFETY INFORMATION

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1.2 Operating Safety
Before operating the machine:
Operator training
 Read and understand the operating instructions contained in all manuals
delivered with the machine.
 Familiarize yourself with the location and proper use of all controls and safety
devices.
 Contact Masalta Corporation for additional training if necessary.
When operating this machine:
 Do not allow improperly trained people to operate the machine. People
operating the machine must be familiar with the potential risks and hazards
associated with it.
Personal Protective Equipment (PPE)
Wear the following Personal Protective Equipment (PPE) while operating this
machine:
 Close-fitting work clothes that do not hinder movement
 Safety glasses with side shields
 Hearing protection
 Safety-toed footwear
Work area
 Make sure the area immediately surrounding the ight Tower is clean, neat,
and free of debris.
 The tower extends up to 3.7m/5.0m (M 42/M 44). Make sure the area above
the trailer is open and clear of overhead wires and obstructions.
Machine setup
 Make sure the machine is on a firm, level surface and will not tip, roll, slide, or
fall while operating.
 Make sure the machine is well-grounded and securely fastened to a good
earthen ground per national and local regulations.
 The trailer must be leveled and the outriggers extended before raising the
tower.
The outriggers must be extended while the tower is up.
 Never connect the machine to other power sources, such as supply mains of
power companies.
Machine integrity
 Do not start a machine in need of repair.
 Do not use the machine if the insulation on any electrical cord is cut or worn
through.
 Do not operate the lights without the protective lens cover in place or with a
lens cover that is cracked or damaged.
 Replace or repair electrical components with components that are identical in
rating and performance to the originals.
While operating the machine
SAFETY INFORMATION

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 Keep the area behind the trailer clear of people and obstructions while raising
and lowering the tower.
 Do not raise the tower or operate the machine in high winds. ower the tower
immediately if high winds or electrical storms are expected in the area.
 Do not raise, lower, or turn the tower while the unit is operating.
 If any part of the tower hangs up, or the winch cable develops slack while
raising or lowering the tower, STOP immediately! Contact an authorized
Masalta service representative.
 Do not disengage the tower locking pin while the tower is up.
 amps become extremely hot in use! Allow the lamps and fixtures to cool
10–15 minutes before handling.
 ower the tower when not in use.



SAFETY INFORMATION
DANGER
DANGER
When the strong wind shakes the machine, lower the tower.
 The strong wind means the speed more than 10m/s
DANGER
DANGER
Make sure the machine is on a firm, level surface and will not tip,
roll, slide, or fall while operating.
 Gradient<5 °
 Turn the wheel away from the curb if the car is facing uphill.
The back of the front tire should be turned into the curb.
DANGER
DANGER
Connect the grounding wire before using.

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1.3 Operator Safety while using Internal Combustion Engines
 DO NOT smoke when refueling the engine or operating the machine.
 DO NOT refuel a hot or running engine.
 A WAYS keep away from all hot or spark-generating objects when
refuel the engine.
 A WAYS refill the fuel tank until the machine has cooled, and in a
well-ventilated environments.
 DO NOT spill fuel when refueling the engine.
 A WAYS take care to use the right type of fuel.
 A WAYS inspect the fuel leakage regularly.
 NEVER perform any work on the machine while it is running. Before
working on it, stop the engine and disconnect the spark plug wire to
prevent accidental starting.
 Avoid prolonged breathing of exhaust gases.
 A WAYS transport and handle fuel only when contained in approved
safety containers.
 Avoid touch or lean against hot exhaust pipes.
 Allow engine to cool before performing any repairs or service.
 A WAYS keep the area around the muffler free of debris such as
leaves, paper, cartons, etc. A hot muffler could ignite the debris and
start a fire.
 NEVER run the engine without air filter.
SAFETY INFORMATION

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1.4 Label locations
SAFETY INFORMATION

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1. Safety and Operating Labels
Label Meaning
DANGER!
Engines emit carbon monoxide; operate
only in well-ventilated area. Read the
Operation Manual for machine
information. No sparks, flames, or
burning objects near the machine. Shut
off the engine before refueling. Use only
clean, filtered unleaded gasoline.
WARNING!
Read and understand the supplied
Operation Manual before operating the
machine. Failure to do so increase the
risk of injury to yourself or others.
WARNING!
Always wear hearing and eye protection
when operating the machine.
NOTICE!
Check the tire pressure before using
everytime.
CAUTION!
To avoid the tower rollover, please lower the
mast when moving, lifting or transporting the
machine.
WARNING!
Hot surface!
Label Meaning
SAFETY INFORMATION

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CAUTION!
Cut off the power before disconnecting light
fixtures or changing lamps.
DANGER!
Do not touch the terminals if your clothing or
skin is wet!
CAUTION!
Secure in transport lock before lifting or
lowing. Be careful when you adjust the light.
CAUTION!
Do not run the machine indoors or in an
closed area.
The specification of Ballast.
WARNING!
Read and understand the supplied
Operation Manual before operating the
machine. Failure to do so increase the risk of
injury to yourself or others.
CAUTION!
Operate outrigger as the instruction.
CAUTION!
Close the rain cover in rainy weather.

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1.6 Service Safety
Precautions
 To reduce the risk of personal injury, read and understand the service
procedures before performing any service to the machine.
 All adjustments and repairs MUST be completed before operation. Do not
operate the machine with a known problem or deficiency! All repairs and
adjustments should be completed by a qualified technician.
 Do not service the machine if your clothing or skin is wet.
Personal Protective Equipment (PPE)
Wear the following Personal Protective Equipment (PPE) while servicing or
maintaining this machine:
 Close-fitting work clothes that do not hinder movement
 Safety glasses with side shields
 Hearing protection
 Safety-toed footwear
In addition, before servicing or maintaining the machine:
 Tie back long hair.
 Remove all jewelry (including rings).
Before servicing the machine
 Turn the engine off before performing maintenance or making repairs.
 Make sure the engine start switch is turned to OFF.
 Make sure the circuit breakers are open (off).
 Make sure the negative terminal on the battery is disconnected.
 Do not perform even routine service (oil / oil filter changes, cleaning, etc.)
unless all electrical components are shut down.
 Make sure water has not accumulated around the base of the machine. If
water is present, move the machine and allow it to dry before servicing.
 If the machine must be started while servicing, keep hands, feet, and loose
clothing away from moving parts on the generator and engine.
Safety devices and modifications
 Replace all safety devices and guards after repair and maintenance.
 Do not modify the machine without the express written approval of the
manufacturer.
Replacing parts and labels
 Replace worn or damaged components.
 Use only spare parts recommended by Masalta.
 Replace all missing and hard-to-read labels.
WARNING
High voltage! This machine produces high voltage capable of causing
serious injury or death.
 Only a qualified electrician should troubleshoot or repair electrical
problems occurring with this machine.
SAFETY INFORMATION

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 Check all external fasteners at regular intervals.
2.1 Preparing the Machine for First Use
To prepare your machine for first use:
1. Make sure all loose packaging materials have been removed from the machine.
2. Check the machine and its components for damage. If there is visible damage,
do not operate the machine! Contact your Masalta dealer immediately
for assistance.
3. Take inventory of all items included with the machine and verify that all loose
components and fasteners are accounted for.
4. Attach component parts not already attached.
5. Add fluids as needed and applicable, including fuel, engine oil, and battery acid.
6. Move the machine to its operating location.
2.2 Locating Light Tower
Positioning
the machine
WARNING
Electric shock or equipment damage hazards.
The tower extends up to 3.7m/5.0m (M 42/M 44). and
could interfere with overhead wires and obstructions.
 Position the machine on a firm, flat surface clear of
overhead wires and obstructions.
 Make sure that there is enough area for outrigger
extensions to be fully extended.
Ground
Connection
Function
For maximum light coverage, locate the ight Tower at ground level
or in a spot higher than the area being lighted.
A ground connection is located on the machine
frame.
The ground connection is used for electrically grounding the ight Tower when
necessary to comply with the National Electrical Code and other federal, state,
and local regulations. For grounding requirements in your area, consult with a
qualified electrician, electrical inspector, or local agency having jurisdiction
over electrical compliance.
 If the ight Tower is used at a construction site, there may be additional
regulations which must be observed.
OPERA
TION

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2.3 Leveling Machine
 evel the machine and extend the outriggers before raising the tower. The
outriggers must remain extended while the tower is up, and keep the machine
braked.
2.3.1 Operation of the outriggers
Put down the outriggers, the outriggers will be locked automatically
When the outriggers can not be turned smoothly, please depress the lock as
indicating arrow.
WARNING
Tipping / falling hazard. Failures to level the machine or extend
the outriggers will severlyreduce the stability of the unit.
OPERATION
Storing
Using
WARNING
If the generator is not fixed on when it is windy, you must put
down the outriggers.
Outriggers

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When you store the outriggers, please depress the lock as indicating arrow.
Press the lock and turn the outriggers on the baseplate of machine.
2.3.2 Operation of brake
Presses the brake pedal, and then pull back the pedal.
Brake
Brake
OPERATION

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Release the brake
2.4 Install the light
Procedure
1. Turn the lamp inside the lamp holder.
Warning Do not turn the lamp overly, it may cause to damage to the
lamp.
2. Inset the lamp holder to the retroreflector.
amp
amp holder
amp holder
Retroreflector
Release
WARNING
Turn the wheel away from the curb if the car is facing
uphill. The back of the front tire should be turned into
the curb.
OPERATION

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3. Tighten the fasteners, fix the lamp holder and retroreflector
4. Fix the light on the light holder but leaving the light is possible to be adjusted
for the suitable lighting angle.
5. Remove the cover of terminal box
6. Fix the wire as the picture showing
7. Connect the wire end into the socket
8. Cover the terminal box
2. Adjusting the lighting angle
OPERATION
OPERATION
Fasteners
Washer
Spring washer
Nut
Terminal box
Upper light
Downside light
Cable

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 Raise the light holder
eft and right
 Adjust the lamp holder
Adjust the lamp holder between the angle inside the range
as following:
1000W Up: <15 degree Down: <90 degree
400W Up: <15 degree Down: <75 degree
Hold the light holder and loose the lock.
Raise the light holder, pull the drop handle down,
fixed the light holder
 Turn the lighting angle of all the lights
Release the reorientation latch, turn the light
holder, fix the light holder.

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Notice: Turn the screw completely to fix the lamp hold after getting the suitable
lighting angle.
2.6 Control Panel
2.7 Raising the Tower (Manual Winch)
Continue rotating the winch handle clockwise until the tower is at the desired
height. Do not overcrank the winch when the tower is fully extended.
Up and down
OPERATION

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2.8 Lowering the Tower (Manual Winch)
Continue rotating the winch handle counterclockwise until the tower is
resting the bottom.
2.9 Manually Starting the Machine
Prerequisites
 Engine oil, fuel, and coolant are at the proper levels
Note: If fuel tank was drained or run dry it may be necessary to bleed fuel lines.
Refer to engine operator’s manual.
 Electrical cable on the tower is in serviceable condition
 Circuit breakers are in their OFF positions
Procedure NOTICE: Starting the engine under load will damage the
machine.
Follow the procedure below to manually start the machine.
1. Press the START switch. This initiates the pre-heat timer,
energizes the fuel
solenoid, and energizes the starter motor.
2. The engine will crank for 10 seconds, and then rest for 10
seconds. If the engine
does not start immediately, the cycle will repeat three (3) times.
3. If the engine does not start after three attempts, the starting
sequence will be
terminated and the Overcrank shutdown indicator will light. See
section
Troubleshooting Automatic Shutdown for help.
4. When the engine starts, the starter motor is disengaged.
Note: After the starter motor has disengaged, the Safety On
WARNING
Electric shock hazard. Do not start the generator if the insulation
on the tower electrical cable is cut or worng through.
OPERATION

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Timer is acti ated.This timer is pre-set for a 12 second delay and
allows oil pressure, high engine temperature, underspeed, and
charge failure to stabilize without triggering the fault.
5. If a fault occurs after the 12 second delay, see section
Troubleshooting Automatic Shutdown. 5. If a fault occurs after the
12 second delay, see section Troubleshooting Automatic
Shutdown.
6. Allow engine to warm up 3mins before operating lights.
7. Turn the light switch in the “ON” position
NOTICE: Do not use starting fluids to aid in starting of engine.
2.10 Stopping the Machine
Prerequisite ights are turned off.
NOTICE: Generator will be damaged if the engine is shut down before turning off
the lights.
Stopping the machine Push the OFF button to de-energize the fuel solenoid.
2.11 Restart the light on (Once the lights are turned off, you can not turn on the
lights immediately)
Make sure the light switch is in the OFF position.
Cooling the light for 20-30mins
Return the light as the order : Start the generator→turn on the power switch→turn
on the light switch
2.12 Transportation
Prerequisites
 Make sure the switch of generator and light are in the OFF position.
 ower the tower down
OPERATION
Notice
The direction of front wheel is opposite with the
direction of steering handle.
WARNING
Block the machine and fixed completely by
rope when transports the machine by car.

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2.13 Storage
 Turn the light to forward
 Hold the light holder and
loose the lock
 Press down the light holder
 ock the light holder by fixed handle after press
down completely.
NOTICE Do not store the light holder vertically
OPERATION