manual - planta magnun
TRANSCRIPT
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GNUM
PRODUCTS LLC
NIGHTBUSTER LIGHT TOWER
MODELS MLT3060 & MLT3080
OPERATORS MANUAL / PARTS OOK
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This manual providas information and procedures to safely operata and maintain tha light tower
and ganerator. For your own safety and protection from physical injury, carafully read, undar-
stand, and observa the safety instructions dascribed in this manual. TH INFORMATlON CON-
TAINED
IN
THIS MANUAL WAS BASED ON MACHINES
IN
PRODUCTION T TH TIME OF
PUBLlCATION. MAGNUM PRODUCTS LLC RESERVES THE RIGHT
TO
CHANGE ANY POR-
TION OF THIS INFORMATION WITHOUT NOTICE.
n angina operators manual was supplied with the machine at the time of its shipment from the
factory. The manual provides detailed operation and maintenance procedures far the angina.
Additional copies of this manual
are
available from the engina manufacturer.
M GNUM
PRODUCTS LLC
215
POWER
ORIVE
BERLlN, WI 54923
PHONE: 920-361-4442
FAX: 920-361-4416
TOLL FREE: 1-800-926-9768
www.m-p-Ilc.com
Engine Make:
_
Engine Serial
# _
Engine Model
#
Generator Make: _
Generator Model
#
Generator Serial
#
Unit Model
# _
Unit Serial
#
2
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T BLE O CONTENTS
TABLE OF CONTENTS
SAFETY NOTES
UNIT SERIAL PLATE
OPERATING SAFETY
ENGINE SAFETY
TOWING SAFETY
SERVICE SAFETY
SPECIFICATIONS
LlGHT TOWER SET UP
RAISING THE TOWER
MAIN
CONTROL PANEL
ENGINE STARTING ANO OPERATION
AUTOMATIC SHUTOOWN
LlGHT OPERATION
AUXILlARY OUTLETS
OERATING FOR ALTITUOE
SHUTTING DOWN
LOWERING THE TOWER
TOWING THE TRAILER
LlFTING THE TRAILER
TROUBLESHOOTING THE LlGHTS
OAILY INSPECTION ANO MAINTENANCE
DECAL LOCATIONS
MANUAL WINCH MAST
ASSEMBlY
FRAME ANO COMPONENTS
METAL ENCLOSURE COMPONENTS
CATERPILLAR ENGINE ANO GENERATOR
MITSUBISHI ENGINE ANO GENERATOR
CONTROL PANELASSEMBlY
CONTROL BOX ASSEMBLY
HIGH PRESSURE SOOIUM LlGHT ASSEMBLY
METAL HALlOE LlGHT ASSEMBLY
QUICK OISCONNECT MAST JUNCTION BOX ASSEMBLY
MAST JUNCTION BOXASSEMBLY
METAL HALlDE BALLAST
BOX
ASSEMBLY
HIGH PRESSURE SOOIUM BALLAST BOXASSEMBLY
GENERATOR ASSEMBLY 6kW
AC CIRCUIT WIRING DIAGRAMS
OC
CIRCUIT WIRING OIAGRAMS
TRAILER LlGHTS WIRING DIAGRAM
JUNCTION BOX WIRING DIAGRAMS
PAGE3
PAGE4
PAGE4
PAGE5
PAGE5
PAGE6
PAGE6
PAGE7
PAGE8
PAGES 9 10
PAGE
PAGE 12
PAGE 12
PAGE 13
PAGE 13
PAGE 14
PAGE 14
PAGE 14
PAGE 15
PAGE 15
PAGE 16
PAGE 17
PAGES 8 2
PAGES22 23
PAGES24 25
PAGES26 27
PAGES28 29
PAGES 30
3
PAGES32
33
PAGE34
PAGE35
PAGE36
PAGE 37
PAGE38
PAGE39
PAGE40
PAGE41
PAGES42 43
PAGES4445
PAGE46
PAGE47
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SAFETY NOTES
Ths manual contains NOTES, CAUTIONS and WARNINGS which must be followed to prevent !he
possibility 1 improper service, damage
lo
!he equipment. or personal injury. The following lormatting
options will apply when calling the readers attention to the NOTES, CAUTIONS and WARNINGS
Notes: Notes contain additional information important to a procedure. The notes called out in this manual
will be included in the regular texl body but the word "Note" will be in BOLO text and !he note will be written
in italics lo make them more visible. For example: Note
Check the engine o/level before startng
CAUTlON: Cautions previde information important to prevent errors which eould damage Ihe equipment.
The cautions called out in Ihis manual will be in BOLO text, in a separate paragraph
or
sentenee trom Ihe
regular texl body. For example:
CAUTION! Always switch all circuit breakers to "OFF" to preven
the
starting of
the generator
under
load.
WARNINGS: Warnings describe conditions
or
practices which could lead to serious personal injury or death
to the aperator or olhers around the equipment. Warnings called out in this manual will
be
in a separate
paragraph, centered and surrounded by a black border, wilh all informalion in BOLO texto For
example:
WARNINGI
Only a
qualified
electrician
may servica
or make
connectione
to Ihe generator. Lethal voltage ie present
at
the connection
lugs when
the
generator is
runningl
lINIT SERIAL PLATE LOCATION
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L ~ ::=J
S i C i l 1 ~ :
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.J
[ I i i ~ - - ,
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li!!L -=:J
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OPER TlNG S FETY
Before using the light lower
be sure
you
read
and understand
all
inslructions! Equipment aparated improperly
ar by untrained parsonnal can be dangerous! Read
the
operating instructions and familiariza yourself with #le
locatian and properuseo all instruments
and
controls. Inexperienced oparators should receive instruction from
somaone familiar
with
the equipment before being allowed
to
operate or sel up Ihe machine.
The area immediataly surrounding
the
light tower should
be
elean,
neat,
and free of debrs.
Posion and operate light towar on a firm, leval surface.
NEVER
start a unit in
need
of repair.
Lowar tower
when
not
in use,
or if
high
winds or electrical slorms
are
expected
in
Ihe
area.
Make certain light !ower
is well
grounded and securely faslened to a good earthen ground.
The tower extends up to
30 n
(gm).
Make
sure
area
aboye trailer is
open
and clear of overhead wires and
obstructions.
Bulbs becoma extramaly
ho!
is usa! Allow
bulb and
light fixture to
cool
10-15 minutes before handling.
Kaap area behind trailer clear of people while raising and lowering masl! NEVER raise, lower or turn
mas!
whila unit is oparating!
Trailer mus!
be
leveled
and
outriggers extended before
raising
tower. Outriggers must
remain
axtended
while tower is up.
If lor any reason any part
of
mast hangs up or
winch
cable develops slack while raising ar lawering tawer,
STOP immadiately! 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
cerd is
cut or
worn
through.
NEVER operate lights without protective lans
cever in
place orwith a
lens
cover thal is cracked ar damaged!
NEVER adjust mast while unit
is
aperating.
ENGINE S FETY
Internal combustion engines present special hazards durng operation
and
fueling! Failure
to
follow the safety
guidelines described below
could
result
in
severe injury or death. Also
read
and follow all safety wamings
described in the
Engine
Operator's Manual. A copy
of
this manual was supplied with unit when il was shipped
from
the
factory.
DO NOT
run engine
indoors or
in
an
area
with poor ventilation unless exhaust hoses
are
used.
DO NOT fill
fue!
tank near
an
opan flame, while smoking, or while
engine
is
running.
DO NOT fill tank
in
an
enelosed
area
with
poor ventilation.
DO NOT touch
or
lean against hat exhaust
pipes
or engine cylinder.
DO NOT operate with
the fuel
tank
cap
loose
or
missing.
DO NOT remove engine coolant cap while engine is ho!.
DO NOT elean
air
filter
with
gasoline
or
other types o low flash point solvents.
Keep area
around
exhaust pipes and air ducts
free
of
debrs to reduce
the chance of
an
accidental
fire.
Shut
the
engine
down
if
any
of
the following conditions
exist
during operation:
A.
Noticeable changa
in
engine speed.
B. Loss of electrical
output.
C.
Equipment connected to the generator overheats.
D. $parking occurs.
E. Englna misfires or Ihere ls excessive engineJgenerator vibralion.
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TOWING S FETY
Towing a Irailer requires care! 80th the !railer and vehicle mus be in goOO condition and securely fastened to
each other to reduce the possibility
of
an accident. Also, some slates require that large trailers be registtlred
and licensed. Contactyour
local Departrnent
of
Transportation office
to
check on license requirements for your
particular unit.
Check tIlat the hilch and coupling on the lowing vehicle are rated equal lO or greater Ihan, the trailer's 'gross
vehicle weight rating' (GVWR). Check tires on traifer for Iread wear. inllation, and condition.
Inspect the hitch and coupling
for
wear
or
damage.
DO
NOT
tow
trailer
using
defective parts!
Make sure the traller hitch and
the
coupling are compatible.
Make
sure
the
coupling
is
securely fastened
lo the vehicle.
Connectsafetychains in a crossing pattem underthe tongue and attach the brake away cable TO THE REAR
BUMPER OF THE TOWING VEHICLE.
Make
sure directional and brake lights on Ihe trailer are eonnected and working properly.
Check that
lug
nuts holding wheels are tight and tIlal none are missing.
Maximum recommended speed
lor
highway lowing is 45 mph. Reeommended off-road towing speed is nol
lo exceed 1 mph or less depending on lerrain.
When towing, mainlain extra space between vehicles and avoid 50ft shoulders, curbs
and
sudden
lane
changes. If you have not pulled a trailer before, practice tuming, stopping, and backing up in an area away
from heavy traffic.
A film 01 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.
REPORTING TR llER S FETY DEFECTS
I you believe your traller
has
a delect whieh eould cause a crash or could cause injury or death. you should
immediately inlorm Ihe National Highway Traffic Salety Adminislration (NHTSA) in addition
lo
notifying
Magnum Products LLC. 1I NHTSA reeeives similar eomplaints.
il
may open an investigalion; and if i l finds
that a safety defeet exists in a group
01
vehicles
it
may order a recall and remedy eampaign. However.
NHTSA cannot become involved in individual problem between you, your dealer, or Magnum Products LLC.
To
contact NHTSA. you
may
either call the Auto Safety Hotline toll-Iree
at
1-888-327-4236 or by lax at:
(202)-366-7882.
Addilional conlact inlormaton can be lound al: www.nhtsa.dot.gov.
SERVICE S FETY
This unit uses high voltage circuits capable 01 causing serious injury or dealh. Only a qualilied electrician
should troubleshoot or repair electrical problems occuring in this equipment.
Belore servicing lighl tower. make sure engine start switch is turned lo 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
waterto
accumulate around the base
ofthe
lighttower se!.
Ifwaler is
presento DO
NOT
service!
NEVER
service electrical compenents
il
cloth ing or skin s wet. I the unt is stored outside, check tIle engine
and generator
lor any
mosture and dry the
unit
before use.
NEVER wash the uni with a
power
washer
or
high pressure hose.
Open main circuit breaker belore disconnecting battery cables.
Keep hands, leet,
and
loase clothing away from moving parts on generator and engine.
Replace all guards and salety devices immedialely aftar servicing.
Replace all missing
and
hard-to-read labels. Labels provide importa
ni
operatng instruclions and
wam of
dangers and hazards.
Make
sure slings, chains. hooks, ramps, jacks, and other types 01 lifting devices are attached securely and
have enough weight-bearing capacity to lift or hold tIle equipment salely. Always remain aware
01
the
pesilion
01
other people around you when lifting the equipment.
6
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SPECIFlC noNS
Engine manufacturer
Engine model
Enginetype
Engine horsepower (standby)
Engine horsepower (primed)
Fuel tank capacity
Fue! consumption
Engine manufacturer
Engine model
Enginetype
Engine horsepower (primad)
Fuel tank capacity
Fuel consumption
Generator manufacturer
Generator modal
Generator output
kW)
Generalor output (kVA)
Generator frequency
Generator output voltage
Generator output (amperes)
Generator power factor
Generator insulation
Ughting type
Ballast type
Lumens
Coverage (approximate)
Maximum height of tower
Length
wilh
mas! stowed
Width
Width with outriggers extended
Height
Weight with fual
Mitsubishi
L3E-W26IML
Diesel, 3-cyl, liquid coolad 4-stroke
12.7
hp
(9.3 Kw) @1800RPM
10.9
hp
(8.0 Kw) @1800 RPM
30 gal. (113.7
L)
.5 gph (1.89
Lph)
Caterpillar
3013
Diesel, 3-cyl, liquid cooled 4-stroke
31.5 hp
(23.5 Kw) @ 2800 rpm
30 gal. (113.7 L)
.5
gph
(1.89
Lph)
Maralhon Electric
332CSA5214
6.0
6.0
6 Hz
1201240V,
single phase
50-25
1.0
Class p
Metal halide or high pressure sodium
Coil
&
core
440,000
5-7 acres (20,235-28,329 sq meters)
30 ft. (9.14
m)
170 in. (452 cm)
48 in. (162.6 cm)
98 in. (345.4 cm)
68 in. (177.8 cm)
1850 lbs (839
kg)
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REAR
JACK
lOCKTHE
~ L T ; : ; R A I L E R
WHEElS
LlGHT TOWER SET UP
GROUNDING
STUD
TONGUE
JACK
1. For maximum light coverage loeate tower at ground level
or
in a spot higher han the area being iUuminated
by
the
lamps.
WARNING I
The tower extends
up to 30 ft 9.14
m).
Make
sure area aboye
the
traller
Is
open
and
clear
of
overhead wlres and obstructlons.
2. Place
the
traller
onlirm
ground Ihal
is
relatively flat. This will make
it
easier
lo
evelthe
Iower. Blockthe wheels
on he trailer
lo keep
it from moving.
3. Connecl a good earthen ground lo the grounding slud on
the
lrame 01 Ihe lrailer near Ihe Irailer tongue.
4. Pull
the
loeking pin on he tongue
jack
and rolale
it
90 untillhe
spring loaded pin snaps
back
into place.
Turn
the
jack han die cloekwise to raise he traller tongue off 01 the towlng vehicle.
5. Pull
the
locking pins
on
the outrlggers and extend each outrigger until the spring loaded locking pin snaps
back into place (A). Pull the loeking pin on the outrigger jacks and rolale them until the
jack
pads are lacing
clown and the spring loaded pin snaps back into place (B).
6. Pull the loeking pin on Ihe rear jack
and
rOlale
il 90
unlil he spring loaded pin snaps back inlo place. Turn
he jack handle cloekwise 10 slart leveling Ihe traller. Adjusl all four jacks by lurning Iheir handles cloekwise
until
they
are firrnly in contact with
the
ground
and
he trailer Is as level as possible
(e).
7. Remove the masl cradle locking pin (D).
e
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RAISING
THE
TOWER
MAST
CABLE
roNGUE
WlNCH
JUNCTION BOX
MAST
W I N C H I ~ ~ J ~ ~ ~ ~
MAST
LOCK
LlGHT
AOJUSTMENT
HARDWARE
1. Betore raising!he lower t may be necessary to adjust the lamps. The lamps may be adjusted up. down, left
or
right
by
ioosening
the
nuts and bolts on
the
lamp fixtures and aiming them in the desired direction. TIghten
the hardware completely and make sure the lamps are connected to the junction box.
WARNING
he
trailer must
be
leveled with the outriggers extended before ralslng the
tower. The outrlggers must remaln extended
while
the
tower
Is up. Failure
to
level
the
traller
or
extend the outrlggers wlll severly reduce the stability
of
the
unlt
and could allow
the
tower
to
tip and fall.
3. Check both sets 1 cables lor excessive wear or damage. Make sure the cables are properly centered in
each pulley.
4.
Check
the
electrical coil cord
t r
damage.
WARNING
Do nol start the unit II the insulation on the eleclrieal eor Is cut or worn
through. Bare wires In contact with
the
mas!
or
frame may energize the
traller and cause electrocution. Repair
or
replaee
cardo
5. Remove the safety pin from the mast lock. Using
the
handle for!he tangue mounted winch (E), raise
the
mast until it
Is
vertical and the tab
on
the mast
is
positioned into the mast lock. The mast lock
should
snap
into place automatically. Secure
lhe
lock with the
safety pin
(F).
9
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R ISING TH TOWER (continued)
6. Afterthe Mas! s up and locked into place, use the winch on the mast
G) to extend the tower
lo
the desired heighl. Extend the mast
slowly, making sure tha! Ihe electrical cord is pulling Ireely Irom
the storage tube. 11 lor any reason, the cable begins to develop
slack or any 1 the lower sections gets stuck, STOP IMMEDI-
ATELY and contact an authorized service center. DO
NOT
EXTENO THE
MAST
BEVOND THE COLOREO MARKON THE
MAST TUBE (H).
7. The mast can
be
rotated by releasing the locking knob al the
bollom 01 the mast 1). Turn the mast until the lights face in the
desired direclion and then tighten the knob.
WARNING!
Never raisa
or lower
the
mast
while the unit
is
operating!
Never remove the safety pin
or mast
lock
while
the
tower
is up Releasing Ihe lock will cause Ihe mast lo fall.
I
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1. M IN
CIRCUIT BREAKER (30A). This breaker will disconnecl power lo Ihe lights and auxiliary outlels.
II will also disable
Ihe
starting circuil il engine slarting
is
attempled
when Ihe main breaker
is
on.
2. INDIVIDUAL CIRCUIT BREAKERS. One breaker is supplied lor each light.
3. BALLAST INDICATOR LlGHTS. Indicates power from Ihe ballast lo each lght.
4.
OUTlET CIRCUIT BREAKER. This breaker is suppled tor the standard 120V GFCI outlet.
5.
AUXIUARV OUTLETS. These supply power lor accessories connected to Ihe generator when the
engine is running and the main circuit breaker is swilched to
Ihe
on
1
posi ion.
The 120V GFCI outlel is standard. Ihe 240V twis lock is optional.
6 ENGINE STARTlNG SWITCH. Keyed switch operates glow plugs. starts and stops engine.
7. ENGINE
GLOW PLUG
INDICATOR. Indicates operation
01
he engine glow plugs.
8. ENGINE
HOUR
METER. Keeps track 01 engine hours
lor
service.
9.
CIRCUIT BREAKER INDICATOR LlGHT. This light indicates ha the main circul breaker mus
be
opened (switched off) before starting Ihe engine.
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ENGINE STARTING
AND
OPERATlON
1.
Check angine oil, fuel
and
coolant levals. Note:
/f tIle engine
was
run out
of fuelor
the fuel tank was
drained, it
may
be necessaty
to b/eed
the fue/lines. Refer
to
tIle engine operation
manual
supplied witll
the un/.
2. Check tha condition 01 the electrical cord on the Inslde 01 the unit.
WARNINGI
Do not start the
unlt If
the Insulation
on
the electrical cor
is
cut
or
worn
through. Bare wlres In contact with the mast or frame may energize the
trailer and cause electrocuton. Repar or replace cord.
3. Check tha
he
main circuit breaker and individual circuit breakers for each 01 he lights is in the
off "O" positlon.
Note: /f
tha red light on the control panel TURN MAIN BREAKER OFF
s
lluminated when the
key
is tumed to the
STARr
postion, the breaker is c/osed (switched on).
ARNINGI
NEVER START THE ENGINE
WITH
ANY
OF
THE
CIRCUIT BREAKERS SWITCHED ONI Any load on
the generator during 8tart up will cause severe
damage or destroy the generator
4.
Tum
the key on he engine start switch to the left "GLOW PLUG" positlon and hold he key in place until
the glow plug indicator tums red. As seon as It's glowing tum Ihe key to the right
lo
tha "START' pesltlon
and hold It until tha angina cranks and starts running. Ralease the key, it will moya to the "RUN"
position.
ACTIVATE GLOW PLUGS
CRANK
ENGINE TO START
RELEASEKEY
OFF
lrr
CAUTION
o not
crank the engine longer than 10 seconds at a time. If the
englnE nol
start,wait
30 seconds
to
allow the starter motor to cool and then repeat the startlng procedure. Excessive
cranking will cause damage 10
Ihe
starter.
5. Note: ff
ol pressure is
not
obtained within
30
seeonds aftar the
key is
switched
to
the RUN position,
the low-oil automatie shutdown will tum
off
tIle fuel supply. stopping the engine. Check the oil level and
tum
the
key
to the OFF pastion to reset the
oil
pressure timer before attempting to restart tIle engine.
6. Onca the engine is running, allow it to reach normal operating temperatura bafore switching any loads.
AUTOMATIC SHUTDOWN
Ths unt
s
equipped with a low oil pressure and high temperature auto-shutdown system. This systam will
automatcally shut off the fuel supply to stop the engine il ol pressure drops too low or the engine exceeds
normal operating temperatura. Return tha switch to the 'OFP position to rese Iha unit after you have
determined the cause of Ihe shutdown.
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LlGHT OPERA
nON
1. Once theengineis
up to
temperature
and
running
smoothly,switch
main
circuitbreaker
(1) to the
on
1 position.
2.
With
maincircuitbreakeron,
switch
eachindividual
circuitbreakerforthe lights(2) loon"1", one al atime.
3. The
ballastindicator
IIghts
(3)
will
come
on
momentarilyasthelightsstrike. As thelightswarm
up
theballastindicatorlightswill continueto get
brighler
and
Ihen
remain
on.
This
confirmsthat
poweriscomingfrcmIheballeststothe
lights.
4. If an indicatorlight
does
not
come
on,
the
ballast
may
need
to
beserviced. If
the
indicatorlight
comeson and stayslitbulIherelatadlight
is
not
iIIuminatad,check
the
bulb.
5. The lightsrequireawarm upperiad of5-15 minutes
beforetheyreachfulloulput. IfIhe lights
are
shut
1 2
3
-
,
$
G =..=
-
: : : I : : ~
! 'i' ! ! ! ! 'l'
! j F-'
down,
theyrequirea
cool-clown
periodof
10
minutesbeforetheycan
be
switched
on
again.
6. The
lighttowerusesfour
1000W bu
lbs.
When
checkingorreplacingthe
bulbs, wipe
them
with
aclean
clolhtoavoid leavinganygrease,
011
residue orfingerprints
on
theglass. Any residue cancreateaho!
spot
on
the bulb,
causingpremature
bu lb
failure.
WARNING!
NEVEROPERATETHEUGHT5WITHOUT
THE
PROTECTlVELEN5
COVER ORWITH ALEN5COVERTHAT 15 CRACKEDOR DAMAGED!
ThebulbsIn
the
IIghtfixturesproduce high temperaturesand oparate
under pressure.Abroken or missing lens covereould cause
the
bulbs
to
shatter,causinginjury.
WARNING!
Bulbs becomeextremelyhot
in
use! Allow bu
lb fixture
to eool 10-15
minutesbeforehandling.
AUXILIARYOUTLETS
Thecontrol
panel
isequippedwith twooutletsforrunning
accessoriesortools from thegenerator. Powerissupplied
toIheouUets any timethe enginelsrunnlngand themain
circuitbreakerisswitchedon
"1", Note:
o
not pu/l more
than 1 W{roro each outlet when the lights are on This
willoverload
he
generatorand
cause
the
majn
circuit
breakertotrip. Should
the
breakerlrip,switchoff thelights,
remove someofthe
load lO
theoutletsand
wait 10
minutes
for
the
bubs
to cool before
tumingthem back
on.
Withallof Ihelightsoff, lhefullgeneratoroutput maybe
usedwiththeoptional
240V
twist-Iockoutlel.
120V GFCI
OUTlET
(STANDARDk
' ~ ,
240VTWIST-LOCK
OUTlET,.
(OPTIONAl) ~ .
"
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DERATING
FOR ALTITUDE
Al! generalor
seIS
are subjecl to derating
tor
altitude and temperature. Although derating should not affect
lhe
operation of the lights, it will reduce the available power lor operating to lools
and
accessories co
necled to the auxilliary outlels. Typical reductions in performance are 2-4% tor every 1000 ft. (305 meters)
of elevation and 1%
per
l F (3-5
0
Cl
increase in ambient air temperature over 72 F (22.2
0
e).
SHUTTING
DOWN
When you have linished using the light
lower
proceed with shul down as follows:
1. Remove any loads from lhe auxillary oullels.
2. Switch lhe individual circuit breakers
tor
each light
lo the
off "O" pesilion.
3. Switch the main circuit breaker lo the off 0" position.
4. Turn the ENGINE START SWITCH lo
Ihe
OFF" position.
LOWERING
THE TOWER
1.
Shut down the lights and engine. Allow lhe lights to
cooll0-15
minutes belore lowering the lower.
2.
Tum
Ihe
masl winch
lo
collapse Ihe
lower lo
it's lowest pesition. Make sure Ihe colled electrical cord
returns to the storage tuba properly.
WARNING!
If the mast hangs up or the winch cable begins to develop slack, STOP
IMMEOIATELYI Excess slack
in the
cable could cause the rnast te
collapse should it free up wlthout warning. Contact an authorized
service center.
3. Rotate Ihe mast so the lights are lacing Ihe rear
of
the trailer and
lhe
mast winch is lacing the trailer
tongue. Tighten the knob
lor
rotating the mast lirmly.
4. Release the mas! lock by pulling Ihe salety pin
on
the mas! lock and pulling the lock free. Turn the
handle
1
the internal winch until lhe
mast
spring begins to pivot lhe tower down. Release the mast lock
and continue
lo
lower lhe tower until il resls in the cradle.
5. After lhe mast is completely down, insert lhe cradle lock pin and secure it with the salety pino
6. Pesilion IighlS
lo
aim al the ground. It the trailer is going to
be
moved, Magnum strongly recommends
thal lhe lights
be
removed trom the
mast
and stowed lor transportalion. On units equipped wilh quick
disconnect tittings
lor
the lights, disconnecllhe power cords from lhe junction
box
al lhe top
1
the mas!.
Replace the dust caps
on lhe
junclion box.
On
other units. remove the junction
box
cover
on
the lop
of the
masl
and disconnect the wires trom Ihe terminal block.
7. Remove
lhe
lighls by removing the nut Ihal holds Ihe light fixture yoke lo lhe cross tube.
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TOWING THE TR ILER
Once the engine
is
shut down
and
the mast and lights are properly stowed, the trailer can
be
made ready
for transporto
1. Raise the rear jack completely and release the locking pin to rotate it up into the travel position. Make
sure the locking pin snaps into place.
2. Raise the outrigger jacks completely and release the jack locking pin to swing the jacks up into the
travel position. Make sure the locking pins snap into place. Release the outrigger locking pins and slide
the outriggers into the trailer frame until the locking pins snap into place.
3. Use the drawbar jack to raise or lower the trailer onto the hitch
of
the towing vehicle. Lock the hitch
coupling and attach the safety chains or cables
to
the vehicle. Release the jack locking pin and rotate
the jack into the travel position. Make sure the locking pin snaps into place.
4.
Connect any trailer wiring to the tow vehicle. Check for proper operation of the stop and signal lights.
5.
Make sure the cradle locking pin is
in
place.
6. Make sure the doors are properly latched.
7. If the trailer is going to
be
driven over rough ground, remove the bulbs from the light fixtures.
8.
Check for proper inflation of the trailer tires.
9. Attach a red flag
to
the end of the mast befo e towing.
10. 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.
Additional towing information
can
be found on page
6.
LlFTING THE TR ILER
When lifting the light tower and trailer, attach
ny
slings, chains or hooks directly to the centrall ifting eye.
The lifting eye is located on the mast between the two light storage brackets.
1.
Make sure the equipment being used to lift the light tower has sufficient capacity. Note:
The
Iight tower
weighs approximate/y 1850 lbs 839
kg
with
a
full tank of fue o
2.
Make sure the cradle locking pin is
in
place.
3.
Always remain aware
of
the position of other people and objects around you as you move the unit.
4.
Use the upper or lower forklift pockets with care. Approach the unit as perpendicular possible to avoid
ny damage to the unit. Make sure the mast winch handle or any other obstructions - clear
of
the
forklift tines before lifting.
CENTRAL
FORKLlFT
LlFTING E Y E ~
POCKETS
\
f ~ ~ ~ ~ ~ ~ ~ ~ ~ FORKLIFT
POCKETS
D
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TROUBLESHOOTING THE LlGHTS
WARNINGI
HIGH VOL T AGE! 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.
MAST L1GHTS OFF BUT BALLAST INDICATORS ON CONTROL PANEL ARE ON:
1. Mast light is too ho!. Allow light to cool 10-15 minutes before restarting.
2. Faulty bulb connection. Check lhat lhe bulb is tight in the socket.
3. Bulb broken. Check
for
broken are tube or ouler bulb jacket, broken or loose components in
bulb envelope or blackeninlVdeposits inside tube.
4. Check Ihe connections inside Ihe masl junction box and eaeh mast light housinlVsocket.
5.
Check lhe mast
coi!
eord for damage and proper connection inside Ihe control box.
MAST L1GHTS OFF
AND
BALLAST INDICATORS ON CONTROL PANEL ARE OFF:
1.
Check lhe conneclions nside the control
box
and nside each ballast box.
2. Generator output incorreol. Check Ihe incoming voltage to lhe bailas!. Inooming voltage should
be 120V
/-
5V. If voltage
Is
incorrect angine speed
may
naed to be adjusted or generalor may
require servioe.
3.
Low
transformer output. The voltage from the transformer should measure 400 to
5 Vrms.
4. Low
or no ballast outpul. With the lixture cord removed Irom lhe mast junction box, the voltage
at Ihe mast eoil cord eonnection should measure 400 lo 445 Vrms. If proper voltage is not
achieved, perform capacitor check to determine if lhe capacitor
or
coil needs to be replaced.
MAST L1GHTS
ON BUT
THE L1GHT OUTPUT
18
LOW:
1.
Fixture or lens dirty. Clean reflective surface inside fixlure
and
bolh inside and outside surfaee
01
glass lens.
2. Bulb wom. Replace bulb due to normal use.
3. Check lhe masl coil cord. masl junetion box and mast light conneetions.
4. Generalor outpUI incorreet. Check Ihe incoming voltage lo lhe ballast. Incoming voltage should
be 120V
/
5V. II voltage is incorreet engine speed
may
need to be adjusted or generalor may
require service.
5.
Low
ballast output. Check ballasl for proper voltage output.
Consult pages 42-43 and page
7
for eleclrical schematics.
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D ILY INSPE TION
1. Inspect condition 1 electrical cords. Do not use light tower il insulation
is
cut or wom through.
2. Check that winch cables are
in
good condition.
Do not
use a cable that is kinked or starting to unravel.
3. Check that the safety pins
lor
the mast and telescoping locking pins are present and secured with a
chain.
4.
Check that the springs located
in
the mast and telescoping locking pins
are
not broken
or
missing.
ENGINE
M INTEN NCE
The periodic Maintenance Schedule below lists basic maintenance intervals lor the engine. For detailed
maintenance procedures refer to the Engine Operator s Manual. A copy of this manual was supplied with
the unit when it was shipped from the factory. For additional
or
replacement copies 01 the Engine
Operator's Manual contact an authorized engine dealer in
your
area.
Every Every Every
Every
Every Every
Every
50 100 200 400 500 800
Two
hours hours
hours hours hours hours
years
Check lor fuel leaks.
Change engine oil.
Clean air cleaner element.
Clean fuel filler.
Check level of battery electrolyte.
Check condition and tension on fan bel .
Replace oil
filter
Check condilion
of
radiator hoses.
Replace fuel filter.
Remove sediment in fuel tank.
Flush radiator.
Replace fan bel .
Check all electrical connections.
Change radiator coclan .
Check valve clearance.
Replace radiator hoses and clamps.
Replace fuel pipes and clamps.
Replace air aleanar element.
Once
ayear or
every six cleanings.
Changa engine oil and filler afiar first
5
hours
of
oparation.
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OECAL LOCATIONS
ONENGINE
F NGU RD
INSIDE
DOOR
INSIDE
DOO
18
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DECAL LOCATIONS
t
ON GENER TOR INSI E
HOUSING OOR
19
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oeC L LOC TIONS
ABOVE RADIATOR (CAT ENGINE)
BELOW RADIATOR
M I T S U , ~ E ~ N : : : G : : : I N : E : ~ ~ - t i l
www.m p lIc.com
INSIDE ANO OUTSIDE
ABOVE
EXHAUST
PIPE
ABOVE
RADIATOR
CAP
UNITSETUP
INSTRUCTION
OECAL
NEXT
TO
GROUND
STUD
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DECALLOCATlONS
ON MANUAL
HOLDER
ON TOP OF BALLAST
ONTOPOF
OXES BOTH
SIDES
_ ~ ~ ~ ~ O N T R O
BOX
ONTOPOF
CONTROLBOX
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M NU LWI
H M STASSEMBLY
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1
2
3
4
5
6
7
8
9
10
12
13
14
15
16
17
18
19
20
2
22
23
24
25
MANUAL WINCH MAST ASSEMBLV
ITEM NO PARTNO
10008
14448
15006
15380
14261
15015
15014
15002
15003
14151
15013
150088
162578
111368
15829
14439
111428
111138
14526
60247
15292
14734
150018
14234
14278
QTY
1
1
1
4
2
3
4
2
1
1
4
1
1
1
1
1
1
1
1
1
1
2
1
1
1
DESCRIPTION
Guard, coil cord
Winch, manual
Cable, mast 27'
Pin, cottar
Pulley,2"
Pin, clavis 1/2 x 1 1/4
Shim, plastic 2"
x
3"
Clamp, cable
Thimbla, cable
Cable, uppar mast 11'
Shim, plastic 2"
x
2"
Section, mast 3"
Section, mast 2"
8racket, junction box
Reflector, mast
Grip, cord
Crossarm, 4-light
Section, mast 4"
Knob, locking
Washer, tlat
80lt, 3/4-10
x
61/2
Nut, nylock 3/4-10
Tube, mast
Pin, clevis
Cord, coil7-conductor (not shown)
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FR ME
NO
COMPONENTS
e
3 ~ ~
3 ~
4
14
4 ~
41
42
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1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
FRAME ANO COMPONENTS
ITEM
NO PARTNO
110658
16088
11054
110578
148458
14261
14234
14222
14326
11082Z
14448
14324
15543B
14521
16830
16741
16835
16999
11100
15976
60096
60504
19637
60503
110946
142576
14223
111466
14146
110518
15380
14275
14663Z
14403
15165
15153
11206
11201
11207
16679
11202
11203
14798
10252
10253
10254
QTY
2
1
1
1
1
1
1
3
4
2
1
2
1
2
1
1
1
1
1
2
10
6
4
6
2
1
2
1
2
1
1
1
1
1
1
1
2
4
10
2
2
8
1
1
1
1
5
OESCRIPTION
Strap, fuel tank
Cap, fuel tank 3.5"
Tank, fuel wf3.5
fill
neck
Weldment, mast post
Kickback spring, mast
Pulley,2"
Pin, clevis 2"
Jack, top wind complete
Ring, retaining
Weldment, outrigger
Winch, manual
Kit, plunger
Weldment, tongue
Chain, safety
Hitch, ball 2"
Hitch, combo (oplional)
Hitch, Lunette ring 3" (optional)
Hitch, Lunette ring 2 1/2 (oplional)
Axle, 2200
lb.
Wheel,13"
Lug nut, axle
Nul, 9/16 - 18
Plate, shackle bracket
Screw, 9 16 18
Bracket, control box
Weldment, control box
Jack, side wind complete
Holder, battery
J-bolt, battery
Weldment, trame
Pin, cotter
Spring, lock
Bar,latch
Pin, cotterless
Pin, roll
8attery, startng
Hub, axle (with wheel studs)
U-boll, axle
Wheel stud, axle
Spring, axle
Tie plate, spring
Nul, 1/2-20 locking
Cable. winch 16' (nol shown)
Kit, handle top wind jack (nol shown)
Kit, handle side wind jack (not shown)
Kil, jack bevel gears(not shown)
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9
4
3
METALENCLOSURECOMPONENTS
1 ~
3 1
~
1
19
2 _ ~
1
5
~
16
18
26
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METAL ENCLOSURE COMPONENTS
ITEM NO.
1
2
3
4
5
6
7
8
9
1
11
12
13
14
15
16
17
18
19
2
21
PART NO.
16560
11061W
11066W
11095
11091Z
15018Z
14797
11096W
11062W
15123
11060W
10224
10220
10219
65406
11097W
11098W
11077W
65407
14459B
14651
QTY
2
1
2
2
1
1
1
1
1
2
1
1
1
2
2
1
1
1
2
1
2
DESCRIPTION
Fender, plastic
Panel, side (L)
Panel, door
Hinge, door
Cradle, mast
Pin, cradle
Bumper, cradle
Panel, radiator cover
Panel, top
Latch, paddle
Panel, rear (Mitsubishi engine)
Bracket, license plate
Light, license plate
Light, tum signal
Light, maker red
Panel, rear (Cat engine)
Panel, side (R)
Panel, front
Light, marker anber
Bracket, door adjusting
Latch, door (not shown)
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CATERPILLAR
ENGINE
NDGEN
ERATOR
3
A
I
i ~
19
8
5
2
t
(
~ ~ ~ ~ ~ ~ ; :
"
~ ~ i / '
' ~ ~ : ~ , : : : : : : : ; / 4
U \ ~ . > - ~ 1 2
0
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1
2
3
4
5
6
7
8
9
10
12
13
14
15
16
17
18
19
20
2
22
23
24
25
26
27
28
29
30
3
32
33
CATERPILLAR ENGINE AND GENERATOR
ITEM NO
PARTNO
11165
11152B
16778
Page
4
11153B
11154
11155
11156
11157
11158
15241
15045
60014
14410
60047
60044
14216
19220
11159
11160
16782
22419B
16683
11161
11162
11163
11164
15074
15073
15695
15493
15492
11129
TV
1
2
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
DESCRIPTION
Radiator, Calerpillar
Bracket, engine
Engine, Caterpillar
Generalor, 6 kW
Brackel, air cleaner
Clamp, air cleaner
Hose, radiator upper
Hose radiator lower
Hose, air cleaner
Housing, air cleaner
Mount, compression
Mount, generalor
Screw, M6 x 35
Bottle, overflow (w/clamp)
Nul, nylock M6
Screw, M5 x
2
Clamp, hose
Hose, overflow
Guard, fan (L)
Guard, fan (R)
Muffler, engine
Bracket, overflow bottle
Solenoid, fuel (not shown)
Kit, fuel filler (nol shown)
Element, air cleaner (nol shown)
Filler, oil (nol shown)
Glow plug, engine (nol shown)
Cable, battery red 38 (nol shown)
Cable battery black 25 (nol shown)
Capacitor, generalor (nol shown)
Diode, generalor (not shown)
Suppressor (nol shown)
Shroud, radiator (not shown)
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ENGINE
NO GENER TOR COMPONENTS
2 ~ :
5 2 ~
t
~ ~ f J >
______ 13
f J > ~
2
ITEMNO
1
2
3
4
5
6
7
8
9
10
2
13
4
15
4
PARTNO
16540
16554B
16553B
16597
Page 4
16551B
16552B
16687
16588
16589
16443
524
15 45B
16535B
1441
1
3
/
25
QTY
1
1
1
1
1
1
1
1
1
1
1
4
1
2
1
16
I
17
~ ~ 5
~ 8
3
19
DESCRIPTION
Radiator, Mitsubishi
Mount, engine L)
Mount, engine R)
Engine, Mitsubishi
Generator, 6
kW
Bracket, air cleaner
Bracket, fuel filter
Hose, radiator upper
Hose radiator lower
Hose, air cleaner
Housing, air cleaner
Mount, compression
Mount, generator
Bracket, radiator
Bottle, overflow
CONTINUED ON NEXT P GE
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ENGINE NO GENER TOR COMPONENTS
ITEMNO
PARTNO
QTV
DESCRIPTION
16 16724
1 Guard, fan
17
19257 1 Fitting, oil drain
18 60501
1 Elbow, 45 deg.
19 19167
1 Hose, oil drain
20 19301
Cap, oH drain
21 16742
1 Fan, engine
22 19219
1 Cap, radiator
23
22419B
1 Bracket, overflow bottle
24 16832 1 Head, fuel filter
25
16686 1 Element, fuel fil ler
26
15266
1 Muffler, engina (nol shown)
27 16677
1
Switch, oil pressure (not shown)
28
16678 1
Switch, temperatura (not shown)
29 16683
1 Solenoid, fuel nol shown)
30
16684 1 Kit, fuel feed (not shown)
31 16689 1 Support, hosa (nol shown)
32 16444
1 Element, air cleaner (not shown)
33 16445
Brackel, air cleaner clamp (not shown)
34 16691
Filler, o (nol shown)
35
16692
1 Belt, altamalor (nol shown)
36 16693
3 Glow plug, engine (nol shown)
37 15074
1 Cable, battery red 38" (nol shown)
38 15073 1 Cable battery black 25" (nol shown)
39 15695 1
Capacilor, generalor (not shown)
40
15493 1 Diode, generator (nol shown)
41
15492
Suppressor (nol shown)
42
15212
Generator, 8 kW (nol shown, oplional)
43
11148 1
Dip stick, engine
oi
(nol shown)
44 11147
Cap, oi filler (not shown)
5
16134
1
Bearing. generalor (nol shown)
46
16833 1 Starter, angine Mitsubishi (nol shown)
47
48
49
16743
16744
16745
1
1
1
Altemator, Mitsubishi (nol shown)
Water pump, Mitsubsh (nol shown)
Thermoslat, Milsubish nol shown)
50 11226
Push rod, engine Milsubishi (nol shown)
51
11228 Lifter, engine Milsubishi (nol shown)
52 11262
Injector, fuel w seals (nol shown)
53 11209 1
Gaskel, valve cover (nol shown)
54
11227 1
Kil, engine gaskel (nol shown)
55 16874
1 Hamess, engine eleclrieal (nol shown)
56
11208
Manual, workshop Mitsubishi
57
16730
Manual, engina parts Milsubishi
58
16729
Manual, angine operation Milsubishi
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CONTROL
PANEL
ASSEMBLY
CATERPILLAR ENGINE
ITEMNO
1
2
3
4
5
6
7
8
10
12
13
,
,
C
J
Cj
PARTNO TY
14248
1
14249 4
65325 4
65388 1
11176
1
11177 1
15085 1
14156
1
14130 1
14137 1
10081
1
16237 1
65415
1
3
12
DESCRIPTION
Breaker, main 30A
Switch, toggle 15A
Light, indicator ballast)
Light, indicator main breaker)
Switch, engine
Indicator, glow plug
Gauge, hourmeter
Breaker, 20A
Outlet, 120V GFIC
Outlet, 240V twist lock optional)
Hinge, panel
Panel, control Cal engine)
Breaker, 40A w/8 kW option)
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CONTROL PANEL ASSEMBLV
MITSUBISHI ENGINE
10
< ~ ~
< l
9
1
O" ~
.
. \;)
:CJ.
7
,
5
12
ITEM NO. PARTNO.
1 14248
2
14249
3
65325
4
65388
5
15195
6 16694
7
15085
8 14156
9
14130
10
14137
11
10081
12
10235
13
65415
14 16734
QTV
1
4
4
1
1
1
1
1
1
1
1
1
1
1
DESCRIPTION
Breaker, main 30A
Switch, t09gle 15A
Light, ndicator (ballast)
Light, indicator (man breaker)
Switch, engine
Indicator, glow plug
Gauge, hourmeter
Breaker, 20A
Outlet, 120V GFIC
Outlet, 240V twist lock (optional)
Hinge, panel
Panel, control (Mitsubishi angine)
Breaker,40A (w/8 kW option)
Panel, control (w/8 k generator option)
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CONTROL BOX ASSEMBLV
7
ITEM NO.
1
3
4
5
6
7
8
9
8
~
I ~
/ {
,
:
,
,
I
PARTNO.
14202
10241
11121
14257B
14201
14841
14203
14204
14219
9
QTV
5
1
1
1
1
1
1
DESCRIPTION
Connector, 3/8 Romex
Clamp, manual holder
Holder, manual
Weldment, control box
Relay, auto shutdown
Breaker, 10A
Strip, terminal
Bar, ground
Connector, 3/4 Romex
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HIGH PRESSURE SODIUM
LlGHT
ASSEMBLV
13
3
8
9
WARNING!
DO NOT MIX HIGH PRESSURE
SOOIM
ANO
METAL HAUDE
BULBS
R PARTSI
ITEM
NO.
PARTNO. QTV
DESCRIPTlON
1 15864
1
Connector, cord
2
597 1
Housng, alumnum
3
14632
1
Yoke, light
4 14166 1
Cord, quck dsconnect (optonal)
5
14634 1
Cord, hard wred light
6
1473
1
Socket, light
7
16758
1 Reflector, aluminum
8
16499 1
Gasket, hood
9
16272 1
Ring, renforcement
1
14784
1
Bulb, hgh pressure sodum
676
1
Support, bu lb
2
16718
1
Ring, clamp
13 1675
1 Lens,lght
14 16757
1
Assembly, cable
15 16759 Fixture, complete (quick disconnect)
16
1676
Fixture, complete (hard wired cord)
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METAL HALIDE LlGHT ASSEMBLV
WARNINGI
DO
NOT MIX HIGH
PRESSURE
SODIM ANO METAL HALlDE
BULaS OR
PARTSI
ITEMNO
1
2
3
4
5
6
7
8
9
1
11
12
13
14
15
16
PARTNO
15864
15971
14632
14166
14634
1473
16758
16499
16272
14217
16761
16718
1675
16757
16746
16747
QTV
1
1
1
1
1
1
1
1
1
1
1
1
1
1
36
DESCRIPTION
Connector. cord
Housing. aluminum
Yoke, light
Cord, quick disconnect optional)
Cord. hard wired light
Socket, light
Reflector, aluminum
Gasket, hood
Ring, reinforcement
Bulb, metal halide
Support, bulb
Ring, clamp
Lens,light
Assembly, cable
Fixture, complete including plug)
Fixture, complete
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QUICK DISCONNECT MAST JUNCTION BOX ASSEMBLV
-
4
7
ITEM NO.
1
2
3
4
5
6
7
PARTNO
14278
15863
15697
16394
15403
15404
15402
QTV
1
5
1
4
4
5
DESCRIPTlON
Cord, coil 7-conductor
Strain relief, cord
Washer, rubber seal
Junctlon box, mast
Plug, quick disconnect female)
Cap, receptacle w/chain
Cover, junction box
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M ST JUNCTlON
BOX
SSEMBLY
ITEM NO
1
2
3
4
5
6
7
-
2 - - - _ - d i
3
PARTNO
QTY
14278 1
15863
1
15697
5
15861
4
16081 1
15217
15864
4
8
DESCRIPTlON
Cord coil7-conductor
Strain relief cord
Washer rubber seal
Nut lock
Junction box mast
Strip terminal
Strain relief. cord
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