POWER PRODUCTS LLC LIGHT TOWER MLT4060MV • MLT4060KV MLT4080KV 00121 OPERATING MANUAL Parts manuals available online! www.m-p-llc.
INTRODUCTION This manual provides information and procedures to safely operate and maintain the Magnum Power Products LLC unit. For your own safety and protection from physical injury, carefully read, understand, and observe the safety instructions described in this manual. Keep a copy of this manual with the unit at all times. Additional copies are available from Magnum Power Products LLC, or can be found at www.m-p-llc.com.
TABLE OF CONTENTS Page INTRODUCTION ................................................................................................................................ 2 SAFETY NOTES ................................................................................................................................ 4 OPERATING SAFETY ....................................................................................................................... 4 ENGINE SAFETY.................................................
SAFETY NOTES 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.
• ALWAYS extend the outriggers and level the unit before raising the mast. DO NOT retract the outriggers while the mast is up. • If for any reason any part of the mast hangs up or the winch cable develops slack while raising or lowering the mast, STOP immediately and contact an authorized service representative. • NEVER use the unit if insulation on the electrical cord is cut or worn through.
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, 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.
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 immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Magnum Power 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.
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 parts manual. Below is a summary of the intended meanings for the symbols used on the decals. UV Safety alert symbol; used to alert you to potential personal injury hazards.
SPECIFICATIONS - MLT4060MV, MLT4060KV MAGNUM MODEL MLT4060MV MLT4060KV Engine Make/Brand................................................................... Mitsubishi ..................................... Kubota Model ............................................................................ L3E-W461ML................................ D1005-E3BG1-MGM-1 EPA Tier ........................................................................ 4f................................................... 4f Type .........
SPECIFICATIONS - MLT4080KV MAGNUM MODEL MLT4080KV Engine Make/Brand.......................................................................................................................... Kubota Model ................................................................................................................................... D1105-E3BG EPA Tier ............................................................................................................................... 4f Type ...................
UNIT DIMENSIONS B A C D E 00213 MLT4060MV/KV, MLT4080KV A B C D E 115 in (2.92 m) 107 in (2.71 m) 25 ft (7.6 m) 68 in (1.73 m) 140 in (3.56 m) Specifications are subject to change without notice.
UNIT SERIAL NUMBER LOCATIONS Refer to the illustration to locate the unit ID tag and Vehicle Identification Number (VIN) tag on the unit. Important information, such as the unit serial number, model number, VIN and tire loading information 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 assistance, you may be asked to provide this information. Unit ID Tag Located on inside of front panel.
COMPONENT LOCATIONS Central Lift Point Control Box Engine Exhaust Mast Switch Battery Forklift Pockets LEFT SIDE Radiator Access Mast Rotation Knob Engine Access Fuel Fill Outriggers RIGHT SIDE 00109 13
LIGHT TOWER SET UP 1. For maximum light coverage, locate the unit at ground level or in a spot higher than the area being illuminated by the lamps. WARNING The mast extends up to 25 ft (7.6 m). Make sure area above the unit is open and clear of overhead wires and obstructions. H DETAIL C J F DETAIL D D DETAIL G C D A E B G DETAIL H 00156 2. Place the unit on firm ground that is relatively flat, then block the wheels to keep it from moving (A). This will make it easier to level the unit. 3.
RAISING THE MAST 1. Set up and level the unit. Refer to “Light Tower Set Up” on page 14. WARNING The unit must be leveled with the outriggers extended before raising the mast. The outriggers must remain extended while the mast is up. Failure to level the unit or extend the outriggers will severely reduce stability and could allow the unit to tip and fall. DETAIL B 2. Check the mast cables for excessive wear or damage. Make sure the cables are properly centered in each pulley (A).
MAIN CONTROL PANEL - MLT4060MV, MLT4060KV 1 3 2 BALLAST INDICATOR LIGHTS MAIN BREAKER 240V 11 I ON TURN MAIN BREAKER OFF 10 I I I 4 ON ON ON O ON O ON O O MAST LIGHT SWITCHES 120V BREAKER OFF GLOW PLUG RUN GLOW PLUG INDICATOR 5 START 9 120V 6 8 7 240V DC BREAKER NEUTRAL BONDED TO FRAME 00165 1. MAIN CIRCUIT BREAKER: This 240V (30A) breaker will disconnect power to the lights and control panel receptacles. 2. LIGHT SWITCHES: One circuit breaker is supplied for each light. 3.
MAIN CONTROL PANEL - MLT4080KV 1 3 2 4 BALLAST INDICATOR LIGHTS POWER PRODUCTS LLC 11 215 POWER DRIVE BERLIN, WI 54923 USA 1-800-926-9768 www.m-p-llc.com MAIN BREAKER 240V I ON 10 120V BREAKER I ON O ON O O 120V BREAKER 5 O OFF GLOW PLUG 240V BREAKER 120V I ON MAST LIGHT SWITCHES 9 8 I ON ON TURN MAIN BREAKER OFF RUN START I 120V ON ON 6 O 7 240V DC BREAKER NEUTRAL BONDED TO FRAME 00166 1.
PRESTART CHECKLIST Before starting the unit, all items in the prestart checklist must be completed. Read and understand ALL safety sections at the beginning of this manual. Ensure all maintenance procedures are up to date. For more information, refer to “General Maintenance ” on page 24 and Basic Maintenance Schedules beginning on page 25. The unit must be level. The unit must be dry. Check for any water inside, on, or near the unit, dry if needed.
AUTOMATIC SHUTDOWN This unit is equipped with a low oil pressure and high coolant temperature automatic shutdown system. This system will automatically shut off the fuel supply to stop the engine if oil pressure drops too low or the engine exceeds normal operating temperature. Return the switch to the “OFF” position to reset the unit after you have determined the cause of the shutdown.
WET STACKING The unit is powered by a diesel engine. Diesel engines are susceptible to wet stacking if lightly loaded. Wet stacking occurs when an engine is run at less than 30% of its full load capacity, causing unburned fuel to accumulate in the exhaust system. Wet stacking can be detected by continuous black exhaust when the unit is under a constant load. It can also cause fouling of injectors and buildup on engine valves.
LOWERING THE MAST ELECTRICALLY LOWERING THE MAST 1. Shut down the lights and engine. Allow the lights to cool 10-15 minutes before lowering the mast. 2. If the trailer is going to be moved, it is recommended that the mast is turned so the lights face toward the back of the unit. To rotate the mast: A. Loosen the mast rotation knob. B. Rotate the mast until the white arrows are aligned and the metal stop tabs are touching. The winch and lights should be facing toward the back of the unit. C.
REMOVING THE LIGHTS FOR TRANSPORTATION 1. On units equipped with quick disconnect fittings for the lights, disconnect the power cords from the junction box at the top of the mast. Replace the dust caps on the junction box. On hard wired units, remove the junction box cover, located on the top of the mast, and disconnect ONLY the mast light wires from the connectors. To release the mast light wires from the connectors, flip the locking levers down and pull out the appropriate wires. 2.
LIFTING THE UNIT When lifting the unit, attach any slings, chains or hooks directly to the central lift point. The central lift point is located on the mast between the two forklift pockets. 1. Make sure the equipment being used to lift the unit has sufficient capacity. For approximate weights, refer to Specifications beginning on page 9. 2. Always remain aware of people and objects around the unit while moving. 3. Use the upper or lower forklift pockets with care.
GENERAL MAINTENANCE Poorly maintained equipment can become a safety hazard. In order for the equipment to operate safely and properly over a long period of time, periodic maintenance and occasional repairs are necessary. NEVER perform routine service (oil/filter changes, cleaning, etc.) unless all electrical components are shut off. Before servicing the unit, always follow the instructions listed below. • • • • • • • • • • • • • Ensure the Engine Start switch is turned to the “OFF/O” position.
BASIC MAINTENANCE SCHEDULE - MITSUBISHI ENGINE Refer to the original equipment manufacturer’s operating manual for a complete list of maintenance requirements. Failure to comply with the procedures as described in the engine operator’s manual will nullify the warranty, decrease performance and cause equipment damage or premature equipment failure. Mainenance records may be required to complete a warranty request. Use the schedule in the following table as a guide for regular maintenance intervals.
BASIC MAINTENANCE SCHEDULE - KUBOTA ENGINE Refer to the original equipment manufacturer’s operating manual for a complete list of maintenance requirements. Failure to comply with the procedures as described in the engine operator’s manual will nullify the warranty, decrease performance and cause equipment damage or premature equipment failure. Maintenance records may be required to complete a warranty request. Use the schedule in the following table as a guide for regular maintenance intervals.
WINCH USE, OPERATION & MAINTENANCE • • • • • • • Keep winch free of dirt, oil, grease, water and other substances. Check all mounting bolts and make sure they are tightened to the recommended torque values. Replace any damaged fasteners. Periodically check all connections to be sure they are tight and free of corrosion. Check cable for visible damage every time winch is operated. Examples of damage are: cuts, knots, mashed or frayed portions, and broken strands. Replace cable immediately if damaged.
TOP-WIND MODELS • Oil Apply a lightweight oil to the screw stem. Grease Grease Grease Oil Oil Oil Oil 00243 TRAILER WHEEL BEARINGS The trailer axles are equipped with a grease zerk fitting to allow lubrication of the wheel bearings without the need to disassemble the axle hub.
TROUBLESHOOTING THE LIGHTS DANGER 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 LIGHTS OFF BUT BALLAST INDICATORS ON CONTROL PANEL ARE ON 1. Mast light is too hot. Allow light to cool 10-15 minutes before restarting. 2. Faulty bulb connection. Check that the bulb is tight in the socket. 3. Bulb broken.
MAST LIGHT CONNECTIONS MAST JUNCTION BOX WIRING 4-LIGHT MAST LIGHT CONNECTIONS 4-LIGHT 2 1 4 3 2 1 4 3 00175 30
TO GND BAR TO GND BAR . . WT GN . . 10 9 8 7 6 5 4 3 2 1 . . . . . . . WT WT WT WT WT WT WT . . . . . . . . . . RD . . BLK BLK . . RED . . . . RD BLK . . . . . GFCI GFCI . RED BLK . . X Y GRN . WHT 8KW UNITS ONLY 20A CB5 20A CB6 30A CB7 . N . . . TO GND BAR TO GND BAR Z G GN . TO GND BAR . . . . . BLK RED BLK RED . . . 12 11 10 9 8 7 6 5 4 3 2 1 . . . . . . YEL RED BLU BLK . . . . . . . . .
"TURN MAIN BREAKER OFF" WARNING LIGHT BLK BLK/YEL ALTERNATOR RED/VIO RD/VI ORG/YEL STARTER CONTROL RESISTANCE BLK/YEL RED/YEL BLU (COM) WHT (HOLD) MAIN BREAKER AUX SWITCH GLOW PLUGS SOLENOID BLK 32 BLK/WHT RED (PULL) RED RED/WHT BLK/YEL VIO/YEL RED/YEL N/C N/O 12V BATTERY TIME DELAY RELAY - + COM RD/VI STARTER SWITCH GRY/VIO GRY/BLU OVERHEAT WARNING SWITCH (N.O.) VI/YL 10 AMP CIRCUIT BREAKER BLK RED BLK/WHT BLK/WHT 90340_C_04.23.13 OIL PRESSURE WARNING SWITCH (N.
"TURN MAIN BREAKER OFF" WARNING LIGHT BLK/YEL ALTERNATOR MAIN BREAKER AUX SWITCH GLOW PLUGS BLK BLK/WHT RED/YEL RED/VIO BLU ORG/YEL STARTER RED RED/WHT VIO/YEL RED/YEL (HOLD) (PULL) BLK SOLENOID N/C N/O 12V BATTERY TIME DELAY RELAY - + COM VIO/WHT STARTER SWITCH BLK/YEL GRY/VIO GRY/BLU OVERHEAT WARNING SWITCH (N.O.) RED 10 AMP CIRCUIT BREAKER BLK RED BLK/WHT BLK/WHT 90339_D_09.10.13 OIL PRESSURE WARNING SWITCH (N.C.
DC WIRING DIAGRAM - ELECTRIC WINCH BL 2 1 WINCH YL SWITCH 1 DOWN UP WT 85 87A YL BL CONTACTOR 1 DOWN PROX. RELAY 87 86 BK RD BK TO B+ OF KEY SWITCH UP PROX. RELAY 87 VI 86 85 RD GN BN BK VI/YL 87A BK BK BK BN 30 30 BK BK BL BN DOWN PROX. SWITCH 1 BN BL - UP PROX. SWITCH 2 + BATTERY 90443_F_07.29.
B R2 BR C ACC LIGHT FUSE 10A ALT CONFIG MTB PIN 12 STARTER SWITCH R1 GND SOL INTERIOR LIGHT PNK BK1 TO GND BAR CIRCUIT BREAKER 20A BK/WT1 GND RD/WT PWR RD GY OPT PASS SW 2 4 OR/YL1 TO CNTRL PANEL START SOL WIRE OR/YL2 TO MAIN BREAKER AUX SWITCH NC PIN TO GND BAR BK/WT2 RPM SENSOR ESTOP 1 3 12 V BATTERY BATTERY DISCONNECT BATTERY DISCONNECT RD + 12 V BATTERY RPM BK BK WT + BK - BK/WT PASS SOLENOID WT - + COM TIME DELAY NO NC BLU YEL/GRN BRN BATTERY C
LEFT TAIL/TURN LAMP RED MARKER LAMP AMBER MARKER LAMP BK BK BK BK WT BK RD WT SPLICE SPLICE SPADE SPADE SPADE BN WT WT BN SPADE SPADE LICENSE PLATE LAMP BK YL WT BN BN GN YL BN WT TRAILER PLUG GN RING WT SPLICE SPADE SPADE BN WT BK RD WT BK BK BK BK RIGHT TAIL/TURN LAMP RED MARKER LAMP AMBER MARKER LAMP 90341_B_12.20.
SERVICE LOG OIL GRADE AND TYPE: ____________________________ BRAND:___________________________________ COOLANT MIXTURE: ______________________________ BRAND:___________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ ______________________________________________
NOTES __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ ___________________________________________________
REV: C PART NO: 33298 01.10.
