POWER PRODUCTS LLC LIGHT TOWER MLT4150MV • MLT4200IV OPERATING MANUAL Parts manuals available online! www.m-p-llc.
INTRODUCTION This manual provides information and procedures to safely operate and maintain the light tower. 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 Power Products LLC reserves the right to change any portion of this information without notice.
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.
• 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 light tower if insulation on the electrical cord is cut or worn through. • NEVER operate the lights without protective lens covers in place or with a lens cover that is cracked or damaged. • Only use mild soap and water to clean the lens covers. Other chemicals may have an adverse effect on the glass.
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.
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 - MLT4150MV/MLT4200IV Read this manual carefully before attempting to use this light tower. 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 MLT4150MV MLT4200IV Engine Make/Brand.........................
UNIT DIMENSIONS Read this manual carefully before attempting to use this light tower. 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 setup, use and service requirements. SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. B C A D MLT4150MV, MLT4200IV 10 E A B C D E 111 in (2.82 m) 110 in (2.79 m) 25 ft (7.
UNIT SERIAL NUMBER LOCATIONS Read this manual carefully before attempting to use this light tower. 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.
COMPONENT LOCATIONS Central Lift Point Emergency Stop Switch Radiator Access Control Box Engine Exhaust Mast Switch Battery Forklift Pockets LEFT SIDE Radiator Access Panel Mast Rotation Knob Engine Access Fuel Fill Outriggers RIGHT SIDE 12
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. WARNING The mast extends up to 25 ft (7.6 m). Make sure area above the trailer is open and clear of overhead wires and obstructions. G DETAIL C H E DETAIL D D DETAIL F C B D A F DETAIL G 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.
RAISING THE MAST 1. Set up and level the trailer as described in “Light Tower Set Up” on page 13. WARNING The trailer 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 trailer or extend the outriggers will severely reduce the stability of the unit and could allow the tower to tip and fall. DETAIL B 2. Check the mast cables for excessive wear or damage.
MAIN CONTROL PANEL - MLT4150MV/MLT4200IV 1 2 3 4 BALLAST INDICATOR LIGHTS MAIN BREAKER 240V POWER PRODUCTS LLC 215 POWER DRIVE BERLIN, WI 54923 USA 1-800-926-9768 www.m-p-llc.com I ON TURN MAIN BREAKER OFF I I 5 I ON ON ON O ON O ON O O MAST LIGHT SWITCHES GLOW PLUG INDICATOR 6 OFF GLOW PLUG RUN START 7 DC BREAKER 8 NEUTRAL BONDED TO FRAME 1.
EMERGENCY STOP SWITCH The unit is equipped with one emergency stop switch, located on the left, side panel. The red switch is clearly labeled “EMERGENCY STOP”. The switch can be accessed and activated with all doors closed and locked. Emergency Stop Switch Activate the emergency stop switch by pushing the red button in until it locks down. This will trip the main circuit breaker which will open the contact disconnecting the load to the connection lugs.
STARTING THE LIGHT TOWER 1. Check that the main circuit breaker and individual circuit breakers for each of the lights are in the “OFF/O” position. Note: When the red “TURN MAIN BREAKER OFF” light is illuminated, the main circuit breaker must be turned “OFF/O”. 2. Turn the key on the engine start switch to the left “GLOW PLUG” position and hold the key in place for five seconds, or until the glow plug indicator turns red (there is no glow plug indicator on Isuzu units).
LIGHT OPERATION 1. Once the engine is up to temperature and running smoothly, switch main circuit breaker (A) to the “ON/I” position. 2. With main circuit breaker on, switch each individual circuit breaker for the lights (B) to “ON/I”, one at a time. BALLAST INDICATOR LIGHTS POWER PRODUCTS LLC I ON TURN MAIN BREAKER OFF I I I ON ON ON O ON O ON O O MAST LIGHT SWITCHES GLOW PLUG INDICATOR OFF GLOW PLUG RUN START 4.
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 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. Tighten the mast rotation knob.
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 TRAILER When lifting the light tower and trailer, 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 light tower has sufficient capacity. Central Lift Point Upper Forklift Pockets Note: Refer to Specifications on page 9 for approximate weights. 2. Always remain aware of the position of other people and objects around you as you move the unit. 3.
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. Maintenance 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 (ISUZU 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 TRAILER WHEEL BEARINGS The light tower is 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 HIGH VOLTAGE. 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 JUNCTION BOX WIRING 2 1 4 3 MAST JUNCTION BOX WIRING 4-LIGHT 28 2 1 4 3 MAST LIGHT CONNECTIONS 4-LIGHT
GEN L2 30A 15A 15A 15A 15A LIGHT SWITCHES BLK BLU BLK BLU 4 5 6 7 8 12 11 10 9 RED GRY 3 RED GRY 1 2 MAST CABLE 1 12 11 10 9 8 7 6 5 4 3 2 CAP 1 RED YEL 4 1 3 2 RED 1 BLK L1 2 BLU BLU BLK RED 3 1 CAP 2 GRY BLK 1 RED 2 2 3 CAP 3 BLU WHT RED BLK 4 1 3 3 2 RED 2 3 1 CAP 4 LED BOARD 1 4 2 RED 3 90454_ORG_08.10.
20 AMP G.F.I OUTLET 20 AMP CIRCUIT BREAKER 20 AMP G.F.I OUTLET 20 AMP CIRCUIT BREAKER GRN BLK BLK RED RED WHT WHT GRN 120 VOLT 30 AMP RV RECPTACLE GRN 240 VOLT 30 AMP TWIST-LOCK RECEPTACLE 30 AMP CIRCUIT BREAKER RED RED GRN 240 VOLT 50 AMP TWIST-LOCK RECEPTACLE 50 AMP CIRCUIT BREAKER (2x5-20R, 1xTT-30, 1xL14-30R, 2x14-50) 90317_ORG_07.06.
240 VOLT 30 AMP TWIST LOCK RECEPTACLE WHT GRN WHT GRN GRN WHT 240 VOLT 50 AMP TWIST LOCK RECEPTACLE 240 VOLT 50 AMP TWIST LOCK RECEPTACLE WHT GRN BLK RED BLK 50 AMP CIRCUIT BREAKER RED RED 30 AMP CIRCUIT BREAKER BLK RED BLK RED RED BLK BLK RED 30 AMP CIRCUIT BREAKER BLK BLK RED 30 AMP CIRCUIT BREAKER 20 AMP CIRCUIT BREAKER BLK RED 240 VOLT 30 AMP TWIST LOCK RECEPTACLE GRN GRN WHT WHT 240 VOLT 50 AMP TWIST LOCK RECEPTACLE 240 VOLT 30 AMP TWIST LOCK RECEPTACLE GRN WHT GR
240 VOLT 30 AMP TWIST LOCK RECEPTACLE 240 VOLT 30 AMP TWIST LOCK RECEPTACLE GRN WHT WHT 240 VOLT 50 AMP TWIST-LOCK RECEPTACLE GRN GRN WHT GRN BLK BLK RED 240 VOLT 30 AMP TWIST-LOCK RECEPTACLE GRN WHT GRN GRN WHT WHT 240 VOLT 30 AMP TWIST-LOCK RECEPTACLE 240 VOLT 30 AMP TWIST-LOCK RECEPTACLE WHT GRN TO MAIN BREAKER BLK BLK BLK 50 AMP CIRCUIT BREAKER RED 50 AMP CIRCUIT BREAKER RED BLK RED BLK 30 AMP CIRCUIT BREAKER RED BLK RED 30 AMP CIRCUIT BREAKER 20 AMP CIRCUIT BREAKER
"TURN MAIN BREAKER OFF" WARNING LIGHT 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 BLK 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.C.
SOLENOID MITSUBISHI ISUZU SOLENOID BLU (COM) WHT (HOLD) RED (PULL) BLU (COM) WHT (PULL) "TURN MAIN BREAKER OFF" WARNING LIGHT VI/YL VI/YL RD/YL RD/YL BLK/YEL ALTERNATOR MAIN BREAKER AUX SWITCH GLOW PLUGS BLK BLK/WHT 34 BLK/YEL RED/VIO BLU ORG/YEL RED/YEL STARTER CONTROL RESISTANCE BLK RED (HOLD) RED RED/WHT BLK/YEL E-STOP SWITCH VIO N/C N/O 12V BATTERY TIME DELAY RELAY - + COM VIO/WHT STARTER SWITCH GRY/VIO GRY/BLU OVERHEAT WARNING SWITCH (N.O.
DC WIRING DIAGRAM - ELECTRIC WINCH BL 2 1 WINCH YL SWITCH 1 DOWN UP WT CONTACTOR 1 UP PROX. RELAY 87 85 87A YL BL DOWN PROX. RELAY 87 86 BK RD BK TO B+ OF KEY SWITCH 86 VI BK 85 87A BK RD GN BN BK VI/YL BK BN 30 30 BK BK BL BN DOWN PROX. SWITCH 1 BL BN UP PROX. SWITCH 2 - BATTERY + 90443_F_07.29.
DC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT INTERIOR LIGHT BATTERY CHARGER EDISON PLUG MTB PIN 12 BLU YEL/GRN BRN ALT CONFIG 16/3 R2 FUSE 10A R1 BATTERY CHARGER BR B STARTER SWITCH C ACC BLK RED LIGHT + - 12 V BATTERY HEATED FUEL FILTER BATTERY DISCONNECT BATTERY DISCONNECT BLK RD/BK BK/WT RD/WT R2 R1 BR B - + 12 V BATTERY STARTER SWITCH C RD/VI 25A FUSE 87 86 85 87A ACC 30 RD/BK TO GND BAR 90323_F_07.26.
TRAILER LIGHTS WIRING DIAGRAM TRAILER PLUG AMBER MARKER LAMP AMBER MARKER LAMP RED MARKER LAMP RED MARKER LAMP TO FRAME STOP-TURN SIGNAL LAMP (LEFT) STOP-TURN SIGNAL LAMP (RIGHT) PLATE LAMP 90341_A_08.07.
SERVICE LOG OIL GRADE AND TYPE: ____________________________ BRAND:___________________________________ COOLANT MIXTURE: ______________________________ BRAND:___________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ ______________________________________________
REV: A PART NO: 33330 09.05.
