POWER PRODUCTS LLC LIGHT TOWER MLT4150MV • MLT4200IV MLT4200IVCAN 00122 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 - MLT4150MV, MLT4200IV MAGNUM MODEL MLT4150MV MLT4200IV Engine Make/Brand................................................................... Mitsubishi...................................... Isuzu Model ............................................................................ S4L2-W461ML.............................. 4LE1NYGV-03 4LE1NYGV-03E EPA Tier ........................................................................ 4f...................................................4i Type .....
SPECIFICATIONS - MLT4200IVCAN MAGNUM MODEL MLT4200IVCAN Engine Make/Brand.......................................................................................................................... Isuzu Model ................................................................................................................................... 4LE1NYGV-03G1 EPA Tier ............................................................................................................................... 4i Type ...........
UNIT DIMENSIONS B A C D E 00214 MLT4150MV, MLT4200IV, MLT4200IVCAN 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 Emergency Stop Switch Control Box Engine Exhaust Mast Switch Battery Forklift Pockets LEFT SIDE Radiator Access Mast Rotation Knob Engine Access Fuel Fill Outriggers RIGHT SIDE 00110 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 E B A G DETAIL H 00157 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 1 2 3 4 BALLAST INDICATOR LIGHTS MAIN BREAKER 240V I ON TURN MAIN BREAKER OFF I I 5 I ON ON ON O ON O ON O O LIGHT SWITCHES GLOW PLUG INDICATOR OFF GLOW PLUG 6 RUN 7 START 8 DC BREAKER NEUTRAL BONDED TO FRAME 00167 1. CIRCUIT BREAKER INDICATOR LIGHT: This light indicates that the main circuit breaker must be opened (switched off) before starting the engine. 2.
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 23 and Basic Maintenance Schedules beginning on page 24. The unit must be level. The unit must be dry. Check for any water inside, on, or near the unit, dry if needed.
“START” position and hold it until the engine cranks and starts running. Release the key, it will move to the “RUN” position. Note: For cold weather conditions, refer to the engine operator’s manual for appropriate glow plug interval. ACTIVATE GLOW PLUGS CRANK ENGINE TO START OFF GLOW PLUG RELEASE KEY OFF OFF RUN GLOW PLUG GLOW PLUG RUN START RUN START START 00203 Do not crank the engine longer than 10 seconds at a time.
5. The lights require a warm up period of 5-15 minutes before they reach full output. If the lights are shut down, they require a cool down period of approximately 10 minutes before they can be switched on again. 6. The light tower uses four 1000W bulbs. When checking or replacing the bulbs, wipe them with a clean cloth to avoid leaving any grease, oil residue or fingerprints on the glass. Any residue can create a hot spot on the bulb, causing premature bulb failure.
SHUTTING DOWN THE UNIT Check with personnel using power supplied by the unit and let them know the power is going to be turned off. Make sure the power shut down will not create any hazards by accidentally turning off equipment that needs to be kept on (pumps, compressors, lights, etc.). When you have finished using the unit, proceed with shut down as follows: 1. Remove any loads from the receptacles. 2. Switch the individual circuit breakers for each light to the “OFF/O” position. 3.
MANUALLY LOWERING THE MAST Do not use this procedure unless it is absolutely necessary. Continuous use of this procedure could damage the planetary gear brake of the winch. This procedure will not work if the planetary gear brake is damaged. 1. Remove the power cables from the two terminals on the winch motor assembly (A). 2. Remove the two flange head screws (B) securing the winch motor assembly to the winch. Retain the screws for reassembly. 3.
4. To ensure proper operation of the jacks, lube the grease fittings located on the leveling jacks. Refer to “Jack Maintenance” on page 26. For maintenance interval information, refer to Basic Maintenance Schedules beginning on page 24. 5. Connect any trailer wiring to the tow vehicle. Check for proper operation of the stop and signal lights. 6. Make sure the mast cradle locking pin is in place. 7. Make sure the doors are properly latched. 8.
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 - 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 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 2 4 MAST LIGHT CONNECTIONS 4-LIGHT 1 2 1 4 3 3 00175 29
GEN L2 30A 15A TO RECEPTACLES 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 CAP 4 LED BOARD 1 1 4 2 RED 90454_A_12.02.
20 AMP G.F.I OUTLET 20 AMP G.F.I OUTLET 20 AMP CIRCUIT BREAKER GRN 20 AMP CIRCUIT BREAKER GRN WHT WHT GRN 120 VOLT 30 AMP RV RECPTACLE 30 AMP CIRCUIT BREAKER GRN 240 VOLT 30 AMP TWIST-LOCK RECEPTACLE 30 AMP CIRCUIT BREAKER BLK BLK RED RED RED RED RED RED BLK TO MAIN BREAKER RED RED RED WHT BLK BLK WHT BLK BLK WHT GRN 240 VOLT 50 AMP TWIST-LOCK RECEPTACLE 50 AMP CIRCUIT BREAKER RED RED WHT BLK BLK (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 RED 20 AMP CIRCUIT BREAKER 240 VOLT 30 AMP TWIST LOCK RECEPTACLE GRN WHT GRN GRN WHT WHT 240 VOLT 50 AMP TWIST LOCK RECEPTACLE 240 VOLT 30 AMP TWIST LOCK RECEPTACLE WHT GRN RED BLK BLK 50 AMP CIRCUIT BREAKER RED BLK RED 20 AMP CIRCUIT BREAKER BLK BLK RED RED BLK BLK RED 20 AMP CIRCUIT BREAKER BLK BLK RED 20 A
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 BLK 30 AMP CIRCUIT BREAKER RED 30 AMP CIRCUIT BREAKER RED RED BLK RED BLK RED BLK RED 30 AMP CIRCUIT BREAKER BLK BLK RED 30 AMP CIRCUIT BREAKER 20 AMP CIRCUIT BREAKER 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
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 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 BN BK VI/YL 87A BK BK GN 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 RPM 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 BK BK - + COM TIME DELAY NO NC BLU YEL/GRN BRN BATTERY CHARGER 16/3 12 V BATTERY B R2 C ACC
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:___________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ ______________________________________________
REV: B PART NO: 33330 01.10.
