Magnum MLT4150, MLT4200, MLT4200ICAN Operating Manual

LIGHT TOWER

MLT4150 • MLT4200 • MLT4200ICAN

OPERATING MANUAL

Parts manuals available online www.magnumpower.com

01129

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.magnumpower.com.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.

Read all of the manuals included with the unit. Each manual details specific information regarding items such as setup, use and service requirements. An engine operator’s manual provides detailed operation and maintenance procedures for the engine. Additional copies of the engine operator’s manual are available from the engine manufacturer.

DO NOT MODIFY or use this equipment for any application other than which it was designed for.

Magnum Power Products LLC recommends that a trained and licensed professional perform all electrical wiring and testing functions. Installation should be in compliance with the National Electrical Code (NEC), state and local regulations and Occupational Safety and Health Association (OSHA) guidelines.

MAGNUM POWER PRODUCTS LLC

215 Power Drive • Berlin, WI 54923

U.S.A.

Phone: 920-361-4442

FAX: 920-361-4416

Toll Free: 1-800-926-9768

www.magnumpower.com

For technical or parts QUESTIONS, please contact the Magnum Power Products LLC Customer

Support or Technical Support team at 1-800-926-9768. Please have your serial number available.

To ORDER SERVICE PARTS, please contact the dealer from which you purchased the unit, or call

Magnum Power Products LLC to locate a dealer in your area.

Engine Make:__________________________________________ Engine Serial Number:___________________________________ Engine Model Number: __________________________________ Generator Make: _______________________________________ Generator Model Number: ________________________________ Generator Serial Number: ________________________________ Unit Model Number:_____________________________________ Unit Serial Number: _____________________________________

CALIFORNIA PROPOSITION 65 WARNING: Diesel engine exhaust and some of its

constituents are known to the state of California to cause cancer, birth defects and

2

WARNING

other reproductive harm.

TABLE OF CONTENTS

INTRODUCTION ................................................................................................................................ 2

SAFETY NOTES ................................................................................................................................ 4

OPERATING SAFETY ....................................................................................................................... 4

ENGINE SAFETY............................................................................................................................... 5

SERVICE SAFETY............................................................................................................................. 6

TOWING SAFETY.............................................................................................................................. 6

REPORTING TRAILER SAFETY DEFECTS ..................................................................................... 7

SAFETY SYMBOL SUMMARY .......................................................................................................... 8

SPECIFICATIONS - MLT4150, MLT4200 .......................................................................................... 9

SPECIFICATIONS - MLT4200ICAN................................................................................................. 10

UNIT DIMENSIONS ......................................................................................................................... 11

UNIT SERIAL NUMBER LOCATIONS ............................................................................................ 12

COMPONENT LOCATIONS ............................................................................................................ 13

LIGHT TOWER SET UP................................................................................................................... 14

RAISING THE MAST........................................................................................................................ 15

RAISING THE MAST WITH ELECTRIC WINCH OPTION............................................................... 16

MAIN CONTROL PANEL ................................................................................................................. 17

PRESTART CHECKLIST ................................................................................................................. 18

EMERGENCY STOP SWITCH ........................................................................................................ 18

STARTING THE UNIT...................................................................................................................... 18

AUTOMATIC SHUTDOWN ..............................................................................................................19

LIGHT OPERATION......................................................................................................................... 19

VOLTAGE REGULATION ................................................................................................................ 20

DERATING FOR ALTITUDE ............................................................................................................ 20

WET STACKING ............................................................................................................................. 20

RECEPTACLE PANEL..................................................................................................................... 20

SHUTTING DOWN THE UNIT ......................................................................................................... 21

LOWERING THE MAST................................................................................................................... 21

LOWERING THE MAST WITH ELECTRIC WINCH OPTION.......................................................... 22

REMOVING THE LIGHTS FOR TRANSPORTATION ..................................................................... 22

TOWING THE UNIT ......................................................................................................................... 22

LIFTING THE UNIT .......................................................................................................................... 23

GENERAL MAINTENANCE .............................................................................................................24

BASIC MAINTENANCE SCHEDULE - MITSUBISHI ENGINE ........................................................ 25

BASIC MAINTENANCE SCHEDULE - ISUZU ENGINE .................................................................. 26

WINCH USE, OPERATION & MAINTENANCE - MANUAL ............................................................. 27

WINCH USE, OPERATION & MAINTENANCE - ELECTRIC ..........................................................27

JACK MAINTENANCE ..................................................................................................................... 28

TRAILER WHEEL BEARINGS ......................................................................................................... 29

LOWER RADIATOR HOSE HEATER OPTION - USE AND MAINTENANCE................................. 29

TROUBLESHOOTING THE LIGHTS ............................................................................................... 30

MAST LIGHT CONNECTIONS ........................................................................................................ 31

AC WIRING DIAGRAM ................................................................................................................... 32

AC WIRING DIAGRAM - RECEPTACLE PANEL ............................................................................ 33

AC WIRING DIAGRAM - RECEPTACLE PANEL OPTIONS (1 OF 2)............................................. 34

AC WIRING DIAGRAM - RECEPTACLE PANEL OPTIONS (2 OF 2)............................................. 35

DC WIRING DIAGRAM .................................................................................................................... 36

DC WIRING DIAGRAM - ELECTRIC WINCH OPTION ...................................................................37

DC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT................................................................ 38

TRAILER LIGHTS WIRING DIAGRAM ............................................................................................ 39

SERVICE LOG ................................................................................................................................. 40

NOTES ............................................................................................................................................. 41

Page

3

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. The following formatting options will apply when calling the reader’s attention to the DANGERS, WARNINGS, CAUTIONS, NOTICES and NOTES.

INDICATES A HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN

Indicates a hazardous situation which, if not avoided, could result in death or serious

Indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.

DANGER

DEATH OR SERIOUS INJURY.

WARNING

injury.

CAUTION

Indicates a hazardous situation which, if not avoided, may result in property or equipment

damage.

Note: Notes contain additional information important to a procedure and will be found within the regular text body of this manual.

OPERATING SAFETY

Before using the unit, be sure to read and understand all of the instructions. This equipment was designed for specific applications; DO NOT modify or use this equipment for any application other than which it was designed for. Equipment operated improperly or by untrained personnel can be dangerous. Read the operating instructions and familiarize yourself with the location and proper use of all instruments and controls. Inexperienced operators should receive instruction from someone familiar with the equipment before being allowed to operate or set up the unit. The following points should be practiced at all times:

• The area immediately surrounding the unit should be dry, clean, and free of debris.

• Position and operate the unit on a firm, level surface.

• NEVER start a unit in need of repair.

• ALWAYS lower the mast when not in use, or if high winds or electrical storms are expected in the area.

• Make certain the unit is securely fastened to a good earthen ground. Follow the National Electrical Code (NEC), state and local regulations.

• NEVER operate the unit on a combustible surface.

• The mast extends up to 30 ft (9.14 m). ALWAYS make sure the area above the unit is open and clear of overhead wires and obstructions.

• Keep area around the unit clear of people while raising and lowering the mast.

• Keep all body parts, clothing, and other loose items clear of winch and cable during operation and while in tension.

• Bulbs become extremely hot during use. Allow bulb and light fixture to cool 10-15 minutes before handling.

• NEVER raise, lower or turn the mast while the unit is operating.

4

• 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 winch cable develops slack while raising or lowering the mast, STOP immediately and contact an authorized service representative.

• NEVER remove safety pin or pull mast locking pin while the mast is up.

• NEVER use the unit if insulation on electrical cord is cut or worn through.

• NEVER operate the lights without protective lens cover 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.

• NEVER operate a unit while tired, distracted, or under the influence of drugs or alcohol.

ENGINE SAFETY

Internal combustion engines present special hazards during operation and fueling. Failure to follow the safety guidelines described below could result in severe injury or death. Read and follow all safety warnings described in the engine operator's manual. A copy of this manual was supplied with the unit when it was shipped from the factory.

• DO NOT run engine indoors or in an area with poor ventilation unless exhaust hoses are used. Diesel engine exhaust contains carbon monoxide, a deadly, odorless and colorless gas which, if inhaled, can cause nausea, fainting or death. Make sure engine exhaust cannot seep into closed rooms or ventilation equipment.

• DO NOT operate the unit on a combustible surface.

• DO NOT fill fuel tank near an open flame, while smoking, or while engine is running. DO NOT fill tank in an enclosed area with poor ventilation.

• DO NOT operate with the fuel tank cap loose or missing.

• DO NOT touch or lean against hot exhaust pipes or engine cylinders.

• DO NOT clean air filter with gasoline or other types of low flash point solvents.

• DO NOT remove engine coolant cap while engine is hot.

• DO NOT operate the unit without a functional exhaust system. Prolonged exposure to sound levels in excess of 85 dB(A) can cause permanent hearing loss. Wear hearing protection when working around a running engine.

• Keep area around exhaust pipes and air ducts free of debris to reduce the chance of an accidental fire.

• Batteries contain sulfuric acid which can cause severe injury or death. Sulfuric acid can cause eye damage, burn flesh or eat holes in clothing. Protective eye wear and clothing are necessary when working on or around the battery. Always disconnect the negative (-) battery cable from the corresponding terminal before performing any service on the engine or other components.

• Shut the engine down if any of the following conditions exist during operation:

1. Noticeable change in engine speed.

2. Loss of electrical output.

3. Equipment connected to the generator overheats.

4. Sparking occurs.

5. Engine misfires or there is excessive engine/generator vibration.

6. Protective covers are loose or missing.

7. If the ambient air temperature is above 120°F (49°C).

5

SERVICE SAFETY

This unit uses high voltage circuits capable of causing serious injury or death. Only a qualified and licensed electrician should troubleshoot or repair electrical problems occurring in this equipment.

• Before servicing, make sure the Control Power switch and circuit breakers are in the OFF (O) position, 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 water to accumulate around the base of the unit. If water is present, DO NOT service.

• ALWAYS use extreme caution when servicing the unit in damp conditions. NEVER service the unit if your skin or clothing is wet. DO NOT allow water to collect/accumulate around the base of the unit. If water is present, DO NOT service. If the unit is stored outside, check the engine and generator for any moisture and dry the unit before use.

• NEVER wash the unit with high pressure hoses or power washers.

• Open the main circuit breaker before disconnecting battery cables.

• Keep all body parts, clothing, and other loose items away from moving parts on the unit.

• Make sure slings, chains, hooks, ramps, jacks, and other types of lifting devices are attached securely and have enough weight-bearing capacity to lift or hold the unit safely. Always remain aware of the position of other people around when lifting the unit.

• NEVER start the unit under load. The circuit breakers must be in the OFF (O) position when starting the unit.

• ALWAYS disconnect the negative (-) battery cable from the corresponding terminal before performing any service on the engine, generator or any other components. Remove the negative (-) battery cable from the corresponding terminal if the unit is to be stored or transported.

• Replace all guards and safety devices immediately after servicing.

• Wear heavy leather gloves when handling winch cables. Never let cables slip through bare hands.

TOWING SAFETY

Towing a trailer requires care. Both the trailer and vehicle must be in good condition and securely fastened to each other to reduce the possibility of an accident. Some states require that large trailers be registered and licensed. Contact your local Department of Transportation office to check on license requirements for your particular unit.

• Check that the hitch and coupling on the towing vehicle are rated equal to, or greater than, the trailer's Gross Vehicle Weight Rating (GVWR).

• Check tires on trailer for tread wear, inflation, and condition.

• NEVER tow trailer using defective parts. Inspect the hitch and coupling for wear or damage.

• Make sure the trailer hitch and the coupling are compatible. Make sure the coupling is securely fastened to the vehicle.

• Connect safety chains in a crossing pattern under the tongue to the rear bumper of the towing vehicle.

• Make sure directional and brake lights on the trailer are connected and working properly.

• Check that all lug nuts holding wheels on are tight and none are missing.

• Maximum recommended speed for highway towing is 45 mph (72 km/h). Recommended off-road towing speed is not to exceed 10 mph (16 km/h) or less, depending on terrain.

• When towing, maintain extra space between vehicles and avoid soft shoulders, curbs and sudden lane changes. If you have not pulled a trailer before, practice turning, stopping, and backing up in an area away from heavy traffic.

6

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. However, NHTSA cannot become involved in an individual problem between you, your dealer, or Magnum Power Products LLC.

To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-888-327-4236 (TTY:1-800-424-9153), go to http://www.safercar.gov; or write to:

Administrator NHTSA 1200 New Jersey Avenue S.E. Washington, DC 20590

You can also obtain other information about motor vehicle safety from http://www.safercar.gov.

7

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.

Hot surface(s) nearby.

Belt/entanglement hazard; keep body parts clear of this area.

Fan hazard; keep body parts clear of this area.

Crush hazard; keep body parts clear of this area.

Ultraviolet radiation hazard; operate only with lens intact.

Asphyxiation hazard; operate in well ventilated area.

Dangerous voltage may be present.

Anchor/tie down point.

Forklift here only.

Use clean diesel fuel only.

Burn/scald hazard; pressurized steam.

Stop engine before fueling.

Fire/explosion hazard; keep open flames away from unit.

Lift here only.

Read and understand the supplied operator’s manual before operating unit.

Unit electrical ground.

00197

8

SPECIFICATIONS - MLT4150, MLT4200

MAGNUM MODEL MLT4150 MLT4200

Engine

Make/Brand................................................................... Mitsubishi......................................Isuzu

Model ............................................................................ S4L2-W461ML .............................. 4LE1NYGV-03 or

Horsepower - prime hp (kW) ........................................ 23.5 (17.5) ....................................31.5 (23.5)

Horsepower - standby hp (kW)..................................... 24.7 (18.4) ....................................34.5 (25.7)

Operating Speed rpm ................................................... 1800 ..............................................1800

Displacement in3 (L) ..................................................... 107.40 (1.76) ................................134.25 (2.20)

Cylinders - qty ............................................................... 4 ....................................................4

Fuel Consumption - 100% prime gph (Lph)................. 1.30 (4.92) ....................................1.80 (6.81)

Battery Type - Group Number ....................................... 24.................................................. 24

Battery Voltage (Quantity per Unit) ............................... 12V (1) ..........................................12V (1)

Battery Rating ............................................................... 440 CCA .......................................720 CCA

Generator

Make/Brand................................................................... Marathon Electric.......................... Marathon Electric

Model ............................................................................ 333CSA3024 ................................334CSA3028

Type, Insulation............................................................. Brushless, F..................................Brushless, F

Generator Set (Engine/Generator)

Output - Standby kW (kVA) ........................................... 15.0 (15.0) ....................................20.0 (20.0)

Output Voltage V ........................................................... 120/240, single phase...................120/240, single phase

Output Amperes 120V (240V) A .................................... 125 (63) ........................................167 (83)

Frequency Hz................................................................ 60.................................................. 60

Power Factor................................................................. 1 (1Ø)............................................1 (1Ø)

4LE1NYGV-03E

Weights

Dry Weight lbs (kg)....................................................... 2015 (914) ....................................2122 (963)

Operating Weight lbs (kg) ............................................ 2413 (1095) ..................................2520 (1143)

Capacities

Fuel Tank Volume gal (L).............................................. 56 (212) ........................................56 (212)

Usable Fuel Volume gal (L).......................................... 56 (212) ........................................56 (212)

Coolant (incl. engine) qt (L) .......................................... 11.6 (11.0).....................................11.6 (11.0)

Oil (incl. filter) qt (L) ...................................................... 5.7 (5.4) ........................................8.6 (8.1)

Maximum Run Time hrs ............................................... 43 .................................................. 31

AC Distribution

Circuit Breaker Size ...................................................... 70 .................................................. 100

Voltage Regulation........................................................ +/-1% ............................................+/-1%

Voltages Available 1Ø ................................................... 120, 240........................................120, 240

Lighting

Lighting Type, Ballast Type ............................................ Metal Halide, Coil & Core .............Metal Halide, Coil & Core

Lumens.......................................................................... 440,000 .........................................440,000

Coverage acres (m2)..................................................... 5 - 7 (20,234 - 28,328) ..................5 - 7 (20,234 - 28,328)

Trailer

Number of Axles............................................................ 1 ....................................................1

Capacity - Axle Rating lbs (kg)..................................... 3000 (1361) ..................................3000 (1361)

Tire Size in.................................................................... 15..................................................15

Hitch - Standard ............................................................ 2" Ball............................................2" Ball

Maximum Tire Pressure psi.......................................... 50..................................................50

Specifications are subject to change without notice.

9

SPECIFICATIONS - MLT4200ICAN

MAGNUM MODEL MLT4200ICAN

Engine

Make/Brand..........................................................................................................................Isuzu

Model ...................................................................................................................................4LE1NYGV-03G

EPA Tier ............................................................................................................................... 4f

Horsepower - prime hp (kW) ...............................................................................................31.5 (23.5)

Horsepower - standby hp (kW)............................................................................................ 34.5 (25.7)

Operating Speed rpm ..........................................................................................................1800

Displacement in3 (L) ............................................................................................................134.25 (2.20)

Cylinders - qty ......................................................................................................................4

Fuel Consumption - 100% prime gph (Lph)........................................................................1.80 (6.81)

Battery Type - Group Number .............................................................................................. 24

Battery Voltage (Quantity per Unit) ......................................................................................12V (1)

Battery Rating ......................................................................................................................720 CCA

Generator

Make/Brand..........................................................................................................................Marathon Electric

Model ...................................................................................................................................334CSA3028

Type, Insulation.................................................................................................................... Brushless, F

Generator Set (Engine/Generator)

Output - Standby kW (kVA) ..................................................................................................20.0 (20.0)

Output Voltage V ..................................................................................................................120/240, single phase

Output Amperes 120V (240V) A ...........................................................................................167 (83)

Frequency Hz....................................................................................................................... 60

Power Factor........................................................................................................................1 (1Ø)

Weights

Dry Weight lbs (kg)..............................................................................................................2122 (963)

Operating Weight lbs (kg) ...................................................................................................2520 (1143)

Capacities

Fuel Tank Volume gal (L).....................................................................................................56 (212)

Usable Fuel Volume gal (L).................................................................................................56 (212)

Coolant (incl. engine) qt (L) .................................................................................................11.6 (11.0)

Oil (incl. filter) qt (L) .............................................................................................................8.6 (8.1)

Maximum Run Time hrs ......................................................................................................31

AC Distribution

Circuit Breaker Size .............................................................................................................100

Voltage Regulation...............................................................................................................+/-1%

Voltages Available 1Ø ..........................................................................................................120, 240

Lighting

Lighting Type, Ballast Type ...................................................................................................Metal Halide, Coil & Core

Lumens.................................................................................................................................440,000

Coverage acres (m2)............................................................................................................5 - 7 (20,234 - 28,328)

Trailer

Number of Axles...................................................................................................................1

Capacity - Axle Rating lbs (kg)............................................................................................ 3000 (1361)

Tire Size in........................................................................................................................... 15

Hitch - Standard ...................................................................................................................2" Ball

Maximum Tire Pressure psi.................................................................................................50

Specifications are subject to change without notice.

10

UNIT DIMENSIONS

B

A

C

D

ABCDE

MLT4150, MLT4200, MLT4200ICAN

Specifications are subject to change without notice.

170 in

(4.32 m)

70 in

(1.78 m)

30 ft

(9.14 m)

68 in

(1.73 m)

E

00209

140 in

(3.56 m)

11

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.

VIN Tag

MANUFACTURED BY/FABRIQUE PAR: Magnum Power Products LLC DATE: 00/0000 GVWR/PNBV: 000KG (0000LBS) COLD INF. PRESS./ PRESS. DE

GAWR / PNBE TIRE / PNEU RIM / JANTE GONF A FROID - KPA(PSI/LPC) SGL / DUAL

EACH AXLE

THIS VEHICLE CONFORMS TO ALL APPLICABLE STANDARDS PRESCRIBED UNDER THE U.S. FEDERAL MOTOR VEHICLE SAFETY STANDARDS(FMVSS) AND CANADIAN MOTOR VEHICLE SAFETY REGULATIONS IN EFFECT ON THE DATE OF MANUFACTURE.

CE VEHICULE EST CONFORME A TOUTES LES NORMES QUI LUI SONT APPLICABLES EN VERTU DU REGLEMENT SUR LA SECURITE DES VEHICULES AUTOMOBILES DU CANADA EN VIGUEUR A LA DATE SA FABRICATION.

00000000000000000

V.I.N./N.I.V.:

XXX000

MODEL:

TYPE:

TRAILER

TIRE AND LOADING INFORMATION

RENSEIGNEMENTS SUR LES PNEUS ET LE CHARGEMENT

The weight of cargo should never exceed 0000KG (0000LBS) Le poids du chargement ne doit jamais depasser 0000KG (0000LBS)

SEE OWNER’S MANUAL FOR

ADDITIONAL

INFORMATION

VOIR LE

MANUEL DE

L’USAGER

POUR

PLUS DE

RENSEIGNEMENTS

Unit ID Tag

Located on inside

of front panel

Manufactured by Magnum Power Products, LLC., a subsidiary of Generac Power Systems, Inc.

(920) 361-4442 (800) 926-9768

Country of Origin

Manufacturing Code

1 ph. 1.0PF 3 ph. .8PF 3 ph. 1.0PF

KW

KVA

V

A

Serial Number

Model

Weight (lbs/kg) RPM/Frequency

Rating

FOR ELECTRICAL EQUIPMENT

ONLY. POUR MATERIAL

ELECTRIQUE SEULEMENT.

209649

Form: SFC626B

Ins. Class

01131

12

COMPONENT LOCATIONS

Mast

Rotation

Knob

Central

Lift Point

Control

Box

Engine Exhaust

Emergency Stop Switch

Battery

Forklift

Pockets

LEFT SIDE

Engine

Access

Radiator

Access

Fuel Fill

Outriggers

RIGHT SIDE

00105

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 30 ft (9.14 m). Make sure area above the unit is open and clear

of overhead wires and obstructions. Do not set up the unit if high winds or storms

capable of producing lightning are expected in the area

H

J

DETAIL C

H

DETAIL D

F

E

D

DETAIL G

B

C

D

E

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. Pull the locking pin on the tongue jack and rotate the jack 90°. Replace the locking pin (B). Turn the jack handle clockwise to raise the trailer tongue off of the towing vehicle.

4. Connect a good earthen ground to the grounding stud on the frame of the trailer at the base of the mast post (C).

Note: Refer to local codes for proper grounding requirements.

G

A

DETAIL H

00152

5. Pull the locking pin (D) on the outrigger (E) and pull each outrigger out until the spring loaded locking pin snaps back into place. Pull the locking pin on the outrigger jack and rotate each jack 90° so the jack pad is facing down. Replace the locking pin.

6. Pull the locking pin on the rear jack (F) and rotate the jack 90°. Replace the locking pin. Turn the jack handle clockwise to start leveling the trailer. Adjust all four jacks by turning their handles clockwise (G) until they are firmly in contact with the ground and the trailer is as level as possible.

14

7. Before raising the mast, it may be necessary to adjust the lamps. The lamps may be adjusted up, down, left or right by loosening the wing nuts on the trunnion (H) and aiming them in the desired direction. Tighten the hardware completely and make sure the lamps are connected to the junction box (J).

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 the

stability and could allow the unit to tip

and fall.

2. Remove mast cradle locking pin from mast cradle (A).

DETAIL A

DETAIL C

DETAIL E

STOP

DETAIL G

3. Check the mast cables for excessive wear or damage. Make sure the cables are properly centered in each pulley (B). Check the electrical cord for damage.

B

G

A

WARNING

Do not start the unit if insulation on the electrical cord is cut or worn through. Bare wires in contact with the mast or frame may energize the unit and cause

electrocution. Repair or replace a

damaged cord.

4. Make sure the area around the unit is clear before raising the mast to the vertical position.

5. Remove the safety pin from the mast lock bar (C). Using the handle for the lower mast winch (D), raise the mast until it is vertical and the tab on the mast is positioned into the mast lock. The mast lock bar should snap into place automatically. Secure the lock with the safety pin (E).

6. After the mast is up and locked into place, use the upper mast winch (F) to telescope the mast to the desired height. Extend the mast slowly, making sure the electrical cord is extending at the top sections of the mast. If, for any reason, the winch cable begins to develop slack or any of the mast sections get stuck, STOP IMMEDIATELY and contact an authorized service center.

F

D

H

B

C, E

00179

Do not extend the mast beyond the colored mark on the middle mast tube (G).

7. Rotate the mast by loosening the mast rotation knob at the bottom of the mast (H). Turn the mast until the lights face in the desired direction and then tighten the knob.

Never raise or lower the mast while the unit is operating. Never remove the safety pin or

release the mast lock while the mast is up. Releasing the lock will cause the mast to fall.

CAUTION

WARNING

15

RAISING THE MAST WITH ELECTRIC WINCH OPTION

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 the

stability and could allow the unit to tip

and fall.

DETAIL C

DETAIL E

DETAIL D

DETAIL F

2. Remove mast cradle locking pin from mast cradle (A).

3. Check the mast cables for excessive wear or damage. Make sure the cables are properly centered in each pulley (B). Check the electrical cord for damage.

B

G

DETAIL G

A

STOP

DETAIL H

WARNING

Do not start the unit if insulation on the electrical cord is cut or worn through. Bare wires in contact with the mast or frame may energize the unit and cause

electrocution. Repair or replace a

damaged cord.

4. Make sure the area around the unit is clear before raising the mast to the vertical position.

5. Remove the safety pin from the mast lock bar (C). Press the lower winch control switch (D) upward to raise the mast into the vertical position. Hold the switch until the mast lock is engaged. The mast lock bar should snap into place automatically. Secure the lock with the safety pin (E).

Note: a limit switch on the mast tube will disconnect power to the lower electric winch to prevent deadheading the winch.

F

D

C,E

B

H

00189

6. Press and hold the upper winch control switch (F) upward to telescope the mast to the desired height. Extend the mast slowly, making sure that the coiled electrical cord is extending at the top sections of the mast. If, for any reason, the winch cable begins to develop slack or any of the mast sections get stuck, STOP IMMEDIATELY and contact an authorized service center.

Do not extend the mast beyond the colored mark on the middle mast tube (G). A limit switch

on the main mast section will disconnect power to the upper electric winch to prevent

7. Rotate the mast by loosening the locking knob at the bottom of the mast (H). Turn the mast until the lights face in the desired direction and then tighten the knob.

Never raise or lower the mast while the unit is operating. Never remove the safety pin or release the mast lock while the mast is up. Releasing the lock will cause the mast to fall.

16

CAUTION

overextending the mast.

WARNING

MAIN CONTROL PANEL

240VAC

MAIN CIRCUIT

BREAKER

ON

12 354

BALLAST INDICATOR LIGHTS

I

ON

ON ON ON ON

O

MAST LIGHT SWITCHES

I

O

6

TURN MAIN

BREAKER

OFF

NEUTRAL BONDED TO FRAME

GLOW

PLUGS

OFF

RUN

START

GLOW PLUG

INDICATOR

7

00163

1. MAIN CIRCUIT BREAKER: This 240V (70A or 100A) breaker will disconnect power to the lights and receptacles.

2. CIRCUIT BREAKER INDICATOR LIGHT: This light indicates that the main circuit breaker must be opened (switched off) before starting the engine.

3. LIGHT SWITCHES: One circuit breaker is supplied for each light.

4. BALLAST INDICATOR LIGHTS: Indicates power from the ballast to each light.

5. ENGINE HOUR METER: Keeps track of engine hours for service.

6. CONTROL POWER SWITCH: Keyed switch operates glow plugs, starts and stops engine.

7. GLOW PLUG INDICATOR: Indicates operation of the engine glow plugs. (Mitsubishi engines only.)

17

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.  Ensure the unit is properly grounded to a good earthen ground. Installation should be in compliance

with the National Electrical Code (NEC), state and local regulations.

 Switch the Control Power switch to the OFF (O) position.  Switch all circuit breakers to the OFF (O) position.  Inspect all electrical cords; repair or replace any that are cut, worn, or bare.  Ensure all winch cables are in good condition and centered on each pulley. Do not use if cables are

kinked or beginning to unravel.

 Check oil, coolant, and fuel levels. For more information, refer to “General Maintenance” on page 24.  Ensure engine battery connections are secure.  Turn the battery disconnect switch on, if equipped.  Ensure the Emergency Stop switch is pulled out.

EMERGENCY STOP SWITCH

The unit is equipped with one emergency stop switch. For location of the emergency stop switch, refer to “Component Locations” on page 13. The red switch is clearly labeled “EMERGENCY STOP.” The switch can be accessed and activated with all doors closed and locked.

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. This will also open the fuel circuit, shutting down the engine.

The switch will remain closed until it is pulled out.

Use the emergency stop switch only when the unit must be shut down immediately. For any

other shut down, refer to “Shutting Down the Unit” on page 21.

STARTING THE UNIT

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 to the OFF (O) position.

2. Turn the key on the Control Power switch to the left Glow Plug position and hold the key in place for five seconds, or until the glow plug indicator turns red. (Kubota units do not have a glow plug indicator.) As

CIRCUIT BREAKERS

I

O

G

E

R

N

E

M

E

I

O

C

Y

S

T

P

O

00230

I

O

00202

18

soon as it is glowing, turn the key to the right Start position and hold it until the engine cranks and starts running.

A

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.

CTIVATE GLOW PLUG

OFF

GLOW

PLUG

RUN

START

CRANK ENGINE TO START

GLOW PLUG

OFF

RUN

START

RELEASE KEY

OFF

GLOW

PLUG

RUN

START

00203

Do not crank the engine longer than 10 seconds at a time. If the engine will not start, wait

30 seconds to allow the starter motor to cool and then repeat the starting procedure.

Excessive cranking will cause damage to the starter.

Note: If oil pressure is not obtained within 15 seconds after the key is switched to the Run position, the low-oil automatic shutdown will turn off the fuel supply, stopping the engine. Check the oil level and turn the key to the OFF position to reset the oil pressure timer before attempting to restart the engine.

3. Once the engine is running, allow it to reach normal operating temperature before switching on any loads.

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.

LIGHT OPERATION

WARNING

NEVER OPERATE THE LIGHTS WITHOUT THE PROTECTIVE LENS COVER OR WITH

A LENS COVER THAT IS CRACKED OR DAMAGED. The bulbs in the light fixtures

produce high temperatures and operate under pressure. A broken or missing lens

cover could cause the bulbs to shatter, causing injury.

1. Once the engine is up to temperature and running smoothly, switch the main circuit breaker (A) to the

A

ON (I) position.

240VAC

MAIN CIRCUIT

2. With main circuit breaker on, switch each individual circuit breaker for the lights (B) to ON (I), one at a time.

BREAKER

ON

IOIOIOI

ON ON ON ON

3. The ballast indicator lights (C) will come on and continue to get brighter as the lights warm up, and then remain on. This confirms that power is coming

TURN MAIN

BREAKER

OFF

from the ballasts to the lights.

4. If an indicator light does not come on, the ballast may need to be serviced. If the indicator light comes on and stays lit but the related light is not illuminated, check the bulb or the mast wiring. Refer to “Trouble-

NEUTRAL BONDED TO FRAME

shooting the Lights” on page 30.

BALLAST INDICATOR LIGHTS

MAST LIGHT SWITCHES

BC

O

OFF GLOW PLUGS

GLOW PLUG

INDICATOR

RUN

START

00148

19

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.

CAUTION

Bulbs become extremely hot when in use. Allow bulb fixture to cool 10-15 minutes before

handling or lowering the mast.

VOLTAGE REGULATION

Units are equipped with an electronic voltage regulator. The voltage regulator controls the output of the generator by regulating the current into the exciter field. The voltage regulator is adjusted before shipment from the factory. Contact Magnum Power Products LLC for additional information before attempting to adjust the voltage regulator.

DERATING FOR ALTITUDE

All units are subject to derating for altitude and temperature; this will reduce the available power for operating tools and accessories connected to the receptacles. Typical reductions in performance are 2-4% for every 1000 ft. (305 m) of elevation and 1% per 10ºF (5.6ºC) increase in ambient air temperature over 72ºF (22ºC).

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. Diesel engines operate properly when applied loads are between 30% and 100% capacity. Appropriate generator sizing is determined by the anticipated load. If the unit is in a wet stack condition, load the unit heavily for five hours or until the exhaust is clear.

RECEPTACLE PANEL

The receptacle panel is equipped with six receptacles for running accessories or tools from the generator. Power is supplied to the receptacles any time the engine is running and the main circuit breaker is switched to the ON (I) position.

Should the main breaker, or any of the individual circuit breakers trip, remove some of the load to the receptacles before turning them back on.

Each receptacle has an individual circuit breaker, located inside the cabinet under a flip-up cover. Each circuit breaker correspond with the receptacle directly below it.

Receptacle Panel

Grounding Stud

00195

With all of the lights off, the full generator output may be used with the receptacles.

Note: To ensure proper grounding, anytime the generator is providing power to any equipment or load panels that do not have a grounded plug, a ground wire MUST BE added between the equipment and the grounding stud on the receptacle panel per the National Electrical Code (NEC), state and local regulations.

20

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 shutdown 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. Switch the main circuit breaker to the OFF (O) position.

4. Turn the Control Power switch to the OFF position.

CIRCUIT BREAKERS

I

OIO

I

ENGINE START SWITCH

OFF

GLOW

PLUG

RUN

START

00201

Note: For extended storage time, disconnect the battery. For extended storage requirements, refer to the engine operator’s manual.

LOWERING THE MAST

1. Shut down the lights and engine. Allow the lights to cool 10-15 minutes before lowering the mast.

2. Loosen the mast rotation knob. Rotate the mast until the white arrows are aligned and the metal stop tabs are touching. Tighten the mast rotation knob.

3. Turn the upper mast winch handle counterclockwise to collapse the mast to its lowest position. Ensure the electrical cord does not get caught in, or pinched by, the mast while it is being lowered.

CAUTION

STOP IMMEDIATELY if the mast hangs up, or the winch cable begins to develop slack.

Excess slack in the cable could cause the mast to collapse, which could result in personal

injury or equipment damage. Contact an authorized service center.

4. Release the mast lock by pulling the safety pin on the mast lock and pulling the lock bar free. Turn the handle of the lower mast winch counterclockwise until the mast rests in the transport cradle.

Note: If the mast lock bar does not pull free, activate the lower winch slightly to relieve pressure on the mast bar.

5. After the mast is completely down, insert the mast cradle locking pin and secure it with the safety pin.

Note: If the trailer is going to be moved, Magnum Power Products LLC strongly recommends the lights be removed from the mast and stowed for transportation. Refer to “Removing the Lights for Transportation” on page 22.

21

LOWERING THE MAST WITH ELECTRIC WINCH OPTION

1. Shut down the lights and engine. Allow the lights to cool 10-15 minutes before lowering the mast.

2. Loosen the mast rotation knob. Rotate the mast until the white arrows are aligned and the metal stop tabs are touching. Tighten the mast rotation knob.

3. Press and hold the upper winch control toggle switch downward to collapse the mast to its lowest position. Ensure the electrical cord does not get caught in, or pinched by, the mast while it is being lowered.

Note: Some electric winch models are equipped with an anti-backlash safety limit switch. This switch will disconnect power to the winch if excess cable slack is detected, preventing accidental lowering of the mast.

CAUTION

STOP IMMEDIATELY if the mast hangs up, or the winch cable begins to develop slack.

Excess slack in the cable could cause the mast to collapse, which could result in personal

injury or equipment damage. Contact an authorized service center.

4. Release the mast lock by pulling the safety pin on the mast lock and pulling the lock bar free. Lower the mast by holding the lower winch control toggle switch to the right until the mast is resting in the transport cradle.

Note: If the mast lock bar does not pull free, activate the lower winch slightly to relieve pressure on the mast bar.

5. After the mast is completely down, insert the mast cradle locking pin and secure it with the safety pin.

Note: If the trailer is going to be moved, Magnum Power Products LLC strongly recommends that the lights be removed from the mast and stowed for transportation. Refer to “Removing the Lights for Transportation” on page 22.

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. Remove the lights by removing the wing nut that holds the light fixture bracket to the cross tube. Attach the lights to the storage brackets (if equipped) located on the mast tube on either side of the central lift point.

00232

TOWING THE UNIT

Once the engine is shut down and the mast and lights are properly stowed, follow these steps to prepare the unit for towing.

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.

22

3. Use the tongue 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. Remove the jack locking pin and rotate the jack into the travel position. Replace the locking pin.

Note: A film of grease on the coupler will extend coupler life and eliminate squeaking. Wipe the coupler clean and apply fresh grease each time the unit is towed.

4. To ensure proper operation of the jacks, lube the grease fittings located on the leveling jacks. Refer to “Jack

Maintenance” on page 28. For maintenance interval information, refer to Basic Maintenance Schedules beginning

on page 25.

5. Connect any trailer wiring to the tow vehicle. Check for proper operation of the direction and brake lights.

6. Make sure the mast cradle locking pin is in place.

7. Make sure the doors are properly latched.

8. If the unit is going to be driven over rough ground, remove the bulbs from the light fixtures.

9. Check for proper inflation of the trailer tires. Refer to Specifications beginning on page 9.

10. Check the wheel lugs. Tighten or replace any that are loose or missing. If a tire has been removed for axle service or replaced, tighten the lugs, in the order shown, to the following specifications:

1

A. Start all lug nuts by hand. B. First pass tighten to 20-25 ft-lbs (27-33 Nm). C. Second pass tighten to 50-60 ft-lbs (67-81 Nm).

4

3

2

5

D. Third pass tighten to 90-120 ft-lbs (122-162 Nm).

Note: After the first road use, re-torque the lug nuts in sequence.

00204

11. Maximum recommended speed for highway towing is 45 mph (72 km/h). Recommended off-road towing speed is not to exceed 10 mph (16 km/h) or less, depending on the terrain.

LIFTING THE UNIT

When lifting the unit, attach any slings, chains or hooks directly to the central lift point.

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. Make sure the cradle locking pin is in place.

3. Always remain aware of people and objects around the unit while moving.

4. Use the upper or lower forklift pockets with care. Approach the unit as perpendicular as possible to avoid any damage to the unit. Make sure the mast winch handles or any other obstructions are clear of the forklift tines before lifting.

Upper Forklift

Pockets

Lower Forklift

Pocket

Central

Lift Point

Lower Forklift

Pocket

01132

23

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 Control Power switch is turned to the OFF (O) position.

• Ensure the circuit breakers are turned to the OFF (O) position.

• Activate (push in) the emergency stop switch.

• Disconnect the negative (-) terminal on the battery.

• Attach a Do Not Start sign to the control panel. This will notify everyone that the unit is being serviced and

will reduce the chance of someone inadvertently trying to start the unit.

• Never wash the unit with a high pressure hose or with any kind of power washer.

• Never wash the engine block or fuel tank with a power washer or steam cleaner. Water may enter the cabinet

and collect in the generator windings or other electrical parts, causing damage.

• If the unit is stored outside, check for water inside the cabinet and generator before each use. If wet, dry the

unit thoroughly before starting.

• Inspect condition of electrical cords. DO NOT use the unit if insulation is cut or worn through.

• Check that winch cables are in good condition

and are centered on each pulley. DO NOT use a cable that is kinked or starting to unravel.

• Check that the safety pins for the mast lock rod

and mast lock bar are present and secured with a chain. Check that the spring located in the mast lock bar is not broken or missing. Check the operation of the mast lock bar.

• Check the wheel lugs. Refer to “Towing the Unit”

on page 22.

• Check coolant levels. Refer to the engine oper-

ator’s manual when determining proper mixture.

○ Coolant is checked visually by inspecting the level in coolant overflow jug near the radiator. ○ Normal operation is between the Full and Add markings on the overflow jug, this is known as “Normal

Range.”

○ WHEN ENGINE IS STOPPED AND COMPLETELY COOL, coolant may be added directly to the jug.

• Check the oil levels. Refer to the engine operator’s manual when determining proper viscosity.

○ DO NOT start the unit if the engine oil level is below the Add mark on the dipstick. ○ Normal operation is between the Full and Add markings on the dipstick. ○ Add oil only if oil level is below cross-hatch pattern on the dipstick. DO NOT OVERFILL crankcase.

• Check fuel level

PROPER MAST CABLE ROUTING

00131

Note: If the engine was run out of fuel or the fuel tank was drained, it may be necessary to bleed the fuel lines. Refer to the engine operator’s manual supplied with the unit.

24

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. For additional or replacement copies of the engine operator’s manual, contact an authorized dealer in your area.

Item Daily

Check Oil Level  Check Coolant Level  Check Fuel Level  Check Tire Pressure  Check All Electrical Connections  Inspect Radiator Fins For Debris, Clean As

Required Inspect Light Tower Winch For Proper Operation  Fuel Tank - Drain Water  Check Air Cleaner  Replace Engine Oil And Oil Filter * Belt And Belt Tension - Inspect And Adjust  Replace Fuel Filter  Drain And Clean Fuel Tank ** Check Glow Plugs  Lubricate Leveling Jacks  Bolts And Nuts On The Engine - Retighten * Replace Heated Fuel Filter (If Equipped)  Inspect Engine Starting Battery  Air Cleaner Element - Clean, Check And Replace  Fuel System - Bleed Air  Water Sedimenter - Drain Water 



50

Hours

250

Hours

400

Hours

500

Hours

1000

Hours

As

Required

* Perform after the initial 50 hours of operation, then on the regularly scheduled interval indicated in the schedule

above.

** Certain conditions may require the fuel tank to be drained and cleaned more often. When operating in extremely

dusty conditions, clean the fuel tank as often as necessary.

25

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. For additional or replacement copies of the engine operator’s manual, contact an authorized dealer in your area.

Item Daily

Check Oil Level  Check Coolant Level  Check Fuel Level  Drain Fuel Filter  Check Tire Pressure  Check All Electrical Connections  Clean Battery  Check Fan Belt Tension (Replace If Necessary)  Inspect Radiator Fins For Debris, Clean As Required  Preheating Condition Check  Check Engine Starting Conditions And Noise Conditions  Check Exhaust Smoke Condition  Inspect Light Tower Winch For Proper Operation  Replace Engine Oil  Replace Fuel Filter Element  Clean Water Sedimenter Element  Electromagnetic Pump Filter Replacement or Cleaning  Check Fan Belt Tension (Replace If Necessary)  Oil Filter Element Replacement  Replace Air Filter Element  Lubricate Leveling Jacks  Replace Heated Fuel Filter (If Equipped)  Inspect Engine Starting Battery 

250

Hours

500

Hours

1000

Hours

26

WINCH USE, OPERATION & MAINTENANCE - MANUAL

PRIOR TO USE

• Inspect rope or cable and replace if damaged.

• Check mounting hardware for proper tightness and re-torque if necessary.

• Gears, ratchet pivot point and shaft bushings must be kept lubricated with a thin oil or grease.

OPERATION

Take Line/Load In:

1. The cable must be securely fastened to the object being lifted and to the winch drum.

2. Always be sure that the cable and cable attachments are not damaged and are strong enough for the load. Ensure there is an adequate safety factor of at least three times the maximum load for all components used.

3. Referring to the Cable In/Cable Out decal on the winch, turn handle according to the specified direction to lift. The ratchet MUST make a loud clicking sound while pulling line in.

Let Line/Load Out:

1. Referring to the Cable In/Cable Out decal on the winch, turn handle according to the specified direction to lower. No clicking will be heard because the brake system is activated.

MAINTENANCE

The following procedures should be performed at least annually:

1. The gears and bushings of the winch must be kept lubricated. Apply a thin film of grease to the gear teeth, and oil the bushings as needed.

2. The ratchet pawl pivot point must be kept lubricated with a thin oil.

3. Do not get oil or grease on the friction discs.

Grease

Oil

Friction Discs

(No Grease/Oil)

WINCH USE, OPERATION & MAINTENANCE - ELECTRIC

• 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. Failure to replace a damaged cable could result in breakage.

• Regularly check brake for slippage or drift. This is detected visually when winch is under load. If winch drum continues to turn after controls are released, the brake may need to be replaced.

• Periodically clean and grease brake assembly. This will ensure proper performance and extend the life of the winch. If winch seems to labor or get excessively hot during the lowering of loads, the brake will need to be serviced or replaced.

00244

27

• Check motor brushes periodically and replace when necessary.

Note: Only the motor brushes and brake assembly require periodic replacement.

PREVENTIVE MAINTENANCE SCHEDULE

Semi-Annually Or

After Each 25 Hours

Of Operation

Maintenance Activity

After First Operation

Before Each Use

Check Fasteners 

Check Electrical Connections 

Clean And Grease Brake Assembly 

Check Motor Brushes 

Visually Check Winch And Control  

MECHANICAL BRAKE

The mechanical brake generates heat when loads are lowered and the wire cable is powered out. Care must be taken to avoid overheating the mechanical brake.

Whine or chatter associated with a new mechanical brake is normal and typically disappears with use.

Overheating the mechanical brake may result in permanent damage to, or failure of, the brake. Replace any damaged brake components before resuming use of the winch.

JACK MAINTENANCE

The following procedures should be performed at least annually.

SIDE-WIND MODELS

• The internal gearing and bushings of the jack must be kept lubricated. Apply a small amount of automotive grease to the internal gearing by removing the jack cover, or if equipped, use a needle nose applicator or standard grease gun on the lubrication point found on the side of the jack near the crank. Rotate the jack handle to distribute the grease evenly.

• A lightweight oil must be applied to the handle unit at both sides of the tube.

• If equipped, the axle bolt and nut assembly of the caster wheel must also be lubricated with the same light weight oil.

TOP-WIND MODELS

• Apply a lightweight oil to the screw stem.

Oil

Grease

Oil

Grease

Oil

00243

28

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. To lubricate the axle bearings, remove the small rubber plug on the grease cap, attach a standard grease gun fitting to the grease zerk fitting and pump grease into the fitting until new grease is visible around the nozzle of the grease gun. Use only a high quality grease made specifically for lubrication of wheel bearings. Wipe any excess grease from the hub with a clean cloth and replace the rubber plug when finished. The minimum recommended lubrication is every 12 months or 12,000 miles (19,312 km). More frequent lubrication may be required under extremely dusty or damp operating conditions.

LOWER RADIATOR HOSE HEATER OPTION - USE AND MAINTENANCE

CAUTION

Improper use of the lower radiator hose heater could result in damage to the engine or

personal injury. Do not modify the location of the lower radiator hose heater.

The following points should be followed when operating a unit equipped with a lower radiator hose heater.

• Ensure the cooling system is full of the proper mixture of water and engine coolant before each heater use.

• The heater is designed for all-night operation, however, 2-5 hours of heating just prior to starting is usually sufficient for proper engine starting.

• The unit must be level to maintain proper orientation of the heater while it is in operation.

• Use only an undamaged, outdoor rated, three-prong grounded 120VAC extension cord with a minimum amperage rating of 10A. Connect the cord to a properly grounded 120VAC, GFCI receptacle.

• Before starting the engine, unplug the extension cord from the power first, then unplug the heater cordset from the extension cord.

29

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. Check for broken arc tube or outer bulb jacket, broken or loose components in bulb envelope

or blackening/deposits inside tube.

4. Check the connections inside the mast junction box and each mast light housing/socket.

5. Check the mast electrical cord for damage and check the cord connections inside the control box.

MAST LIGHTS OFF AND BALLAST INDICATORS ON CONTROL PANEL ARE OFF

1. Check the connections inside the control box and inside each ballast box.

2. Generator output incorrect. Check the incoming voltage to the ballast by checking the available voltage

on the duplex receptacle. Incoming voltage should be 120V +/- 5V. If voltage is incorrect, the engine speed may need to be adjusted or generator may require service.

3. Low transformer output. The voltage from the transformer should read approximately 400 VAC as the

light “strikes” (induces an arc), then drop and slowly rise back up to stabilize at 240-260 VAC. On quick disconnect models, measure across the junction box terminals when the light is unplugged. On hard wired models, remove the mast junction box cover and insert the wire probes into the connector blocks for the light and ground. If proper voltage is not achieved, perform capacitor check to determine if the capacitor or coil needs to be replaced.

MAST LIGHTS ON BUT THE LIGHT OUTPUT IS LOW

1. Fixture or lens is dirty. Clean reflective surface inside fixture and both inside and outside surface of glass

lens. Use mild soap and water to clean lens. Other chemicals may have an adverse effect on the glass.

2. Bulb worn due to normal use. Replace bulb.

3. Check the mast coil cord, mast junction box and mast light connections.

4. Generator output incorrect. Check the incoming voltage to the ballast. Incoming voltage should be 120V

+/- 5V. If voltage is incorrect, engine speed may need to be adjusted or generator may require service.

5. Low transformer output. The voltage from the transformer should read approximately 400 VAC as the

light “strikes” (induces an arc), then drop and slowly rise back up to stabilize at 240-260 VAC. On quick disconnect models, measure across the junction box terminals when the light is unplugged. On hard wired models, remove the mast junction box cover and insert the wire probes into the connector blocks for the light and ground. If proper voltage is not achieved, perform capacitor check to determine if the capacitor or coil needs to be replaced.

If problems persist, contact Magnum Power Products LLC Technical Service at 1-800-926-9768 for assistance.

30

MAST LIGHT CONNECTIONS

MAST JUNCTION BOX WIRING

4-LIGHT

MAST LIGHT CONNECTIONS

4-LIGHT

21

2

1

43

4

3

00175

31

AC WIRING DIAGRAM

BL

3

RD

2

BK

LED BOARD

YL

BL

WT

GN

3

BK

WT

GN

1

BK

RD

WT

BK

GN

CAP 4

14

23

RD

BK

CAP 2 CAP 3

14

23

GN

4

WT

BK

WT

GN

2

BK

YL

BL

WT/BK

CAP 1

MAST CABLE

GY

BL

BK

RD

GY

BL

BK

RD

BLU

BLK

BLU

BLK

RED

GRY

1

2

9876543

11

10

12

3 1

RD

2

BK

3 1

RD

2

BK

3 1

RD

2

BK

1

2345678

BL

12 43

TRANSFORMERS

9

11

10

12

MAIN

CIRCUIT

TO RECEPTACLES

BREAKER

L1

GEN

LIGHT SWITCHES

RD

BK

15A 15A

RD

BK

15A 15A

30A

L2

RD

BK

RD

BK

90454_B_06.21.14

32

AC WIRING DIAGRAM - RECEPTACLE PANEL

BREAKER TO MAIN

BLK

RED

BLK

RED

BLK

RED

BLK

RED

50 AMP

CIRCUIT

BREAKER

50 AMP

CIRCUIT

30 AMP

CIRCUIT

BREAKER BREAKER

BLK

RED

BLK

RED

BLK

RED

50 AMP

240 VOLT

50 AMP

240 VOLT

30 AMP

240 VOLT

TWIST-LOCK

RECEPTACLE RECEPTACLE

TWIST-LOCK

RECEPTACLE

WHT

GRN GRN

WHT

GRN

WHT

TO NEUTRAL

TO GROUND

WHT

GRN

30 AMP

CIRCUIT

BREAKER

BLKBLK

20 AMP

CIRCUIT

BREAKER

RED

20 AMP

CIRCUIT

RED

BREAKER

30 AMP

120 VOLT

WHT

G.F.I

20 AMP

G.F.I

20 AMP

GRN

RV RECPTACLE

WHT

GRN

RECEPTACLE

GRN

(2x5-20R, 1xTT-30, 1xL14-30R, 2x14-50)

RECEPTACLE

90317_ORG_07.06.11

33

AC WIRING DIAGRAM - RECEPTACLE PANEL OPTIONS (1 OF 2)

TO GROUND

TO NEUTRAL

TO MAIN

BREAKER

20 AMP

G.F.I

OUTLET

20 AMP

G.F.I

OUTLET

20 AMP

CIRCUIT

BREAKER

20 AMP

CIRCUIT

BREAKER

GRN

WHT

RED

20 AMP

G.F.I

OUTLET

GRN

20 AMP

CIRCUIT

BREAKER

BLKBLK

WHT

GRN

WHT

30 AMP

CIRCUIT

BREAKER

240 VOLT

30 AMP

TWIST LOCK

RECEPTACLE

GRN

RED

BLK

RED

BLK

RED

BLK

WHT

30 AMP CIRCUIT

BREAKER

240 VOLT

30 AMP

TWIST LOCK

RECEPTACLE

GRN

RED

BLK

RED

BLK

WHT

RED

50 AMP

CIRCUIT

BREAKER

RED

240 VOLT

50 AMP

TWIST LOCK

RECEPTACLE

GRN GRN

WHT

BLK

50 AMP

CIRCUIT

BREAKER

240 VOLT

50 AMP

TWIST LOCK

RECEPTACLE

RED

WHT

Receptacle Panel (2x5-20R, 2xL6-30R, 2xL14-50) 90315_ORG_10.14.11

TO GROUND

TO NEUTRAL

GRN

WHT

RED

20 AMP

G.F.I

OUTLET

GRN

20 AMP

CIRCUIT

BREAKER

BLKBLK

240 VOLT

WHT

GRN

WHT

TWIST LOCK

RECEPTACLE

30 AMP

CIRCUIT

BREAKER

30 AMP

TO MAIN

BREAKER

RED

BLK

RED

BLK

RED

BLK

TWIST LOCK

GRN

RECEPTACLE

WHT

CIRCUIT BREAKER

240 VOLT

30 AMP

RED

BLK

RED

BLK

TWIST LOCK

GRN

RECEPTACLE

WHT

RED

30 AMP

CIRCUIT

BREAKER

RED

240 VOLT

30 AMP

GRN GRN

WHT

BLK

TWIST LOCK

RECEPTACLE

CIRCUIT

BREAKER

240 VOLT

50 AMP

RED

50 AMP

RED

WHT

BLK

Receptacle Panel (2x5-20R, 3xL6-30R, 1xL14-50)

RED

20 AMP

G.F.I

OUTLET

20 AMP

CIRCUIT

BREAKER

GRN

20 AMP

CIRCUIT

BREAKER

RED

20 AMP

G.F.I

OUTLET

GRN

Receptacle Panel (2x5-20R, 3xL6-20R, 1x50A) 90319_ORG_07.06.11

34

90318_ORG_07.06.11

TO GROUND

TO NEUTRAL

GRN

WHT

BLKBLK

240 VOLT

WHT

TWIST LOCK

RECEPTACLE

CIRCUIT

BREAKER

20 AMP

GRN

RED

WHT

TO MAIN

BREAKER

BLK

20 AMP CIRCUIT BREAKER

240 VOLT

20 AMP

TWIST LOCK

RECEPTACLE

GRN

RED

BLK

RED

BLK

240 VOLT

TWIST LOCK

RECEPTACLE

WHT

RED

BLK

20 AMP

CIRCUIT

BREAKER

BLK

RED

20 AMP

GRN GRN

WHT

50 AMP

CIRCUIT

BREAKER

240 VOLT

50 AMP

TWIST-LOCK

RECEPTACLE

RED

BLK

RED

WHT

AC WIRING DIAGRAM - RECEPTACLE PANEL OPTIONS (2 OF 2)

TO GROUND

TO NEUTRAL

TO MAIN

BREAKER

20 AMP

G.F.I

OUTLET

20 AMP

G.F.I

OUTLET

20 AMP

CIRCUIT

BREAKER

20 AMP

CIRCUIT

BREAKER

GRN

WHT

RED

20 AMP

G.F.I

OUTLET

GRN

20 AMP

CIRCUIT

BREAKER

BLKBLK

WHT

GRN

WHT

30 AMP

CIRCUIT

BREAKER

240 VOLT

30 AMP

TWIST LOCK

RECEPTACLE

GRN

RED

BLK

RED

BLK

30 AMP

CIRCUIT BREAKER

RED

BLK

240 VOLT

30 AMP

TWIST LOCK

RECEPTACLE

GRN

WHT

Receptacle Panel (2x5-20R, 3xL14-30R, 1x50A)

TO GROUND

TO NEUTRAL

GRN

WHT

RED

20 AMP

G.F.I

OUTLET

GRN

20 AMP

CIRCUIT

BREAKER

BLKBLK

WHT

GRN

WHT

RECEPTACLE

30 AMP CIRCUIT

BREAKER

240 VOLT

30 AMP

TWIST-LOCK

GRN

TO MAIN

BREAKER

RED

BLK

RED

30 AMP

CIRCUIT

BREAKER

BLK

RED

240 VOLT

30 AMP

TWIST-LOCK

RECEPTACLE

GRN

WHT

RED

BLK

RED

BLK

WHT

RED

BLK

RED

WHT

RED

30 AMP CIRCUIT BREAKER

RED

240 VOLT

30 AMP

TWIST LOCK

RECEPTACLE

GRN GRN

WHT

RED

30 AMP

CIRCUIT

BREAKER

RED

240 VOLT

30 AMP

TWIST-LOCK

RECEPTACLE

GRN GRN

WHT

BLK

50 AMP

CIRCUIT

BREAKER

BLK

240 VOLT

50 AMP

TWIST-LOCK

RECEPTACLE

90320_ORG_07.06.11

BLK

30 AMP CIRCUIT

BREAKER

BLK

240 VOLT

30 AMP

TWIST-LOCK

RECEPTACLE

RED

BLK

RED

WHT

RED

BLK

RED

WHT

Receptacle Panel (2x5-20R, 4xL14-30R)

RED

20 AMP

G.F.I

OUTLET

20 AMP

CIRCUIT

BREAKER

GRN

20 AMP

CIRCUIT

BREAKER

RED

20 AMP

G.F.I

OUTLET

GRN

Receptacle Panel (2x5-20R, 2xTT-30, 2x14-50) 90355_ORG_07.06.11

90321_ORG_07.06.11

TO GROUND

TO NEUTRAL

GRN

WHT

BLKBLK

WHT

RV RECPTACLE

30 AMP

CIRCUIT

BREAKER

120 VOLT

30 AMP

GRN

TO MAIN

BREAKER

RED

BLK

RED

30 AMP

CIRCUIT

BREAKER BREAKER

RED

120 VOLT

30 AMP

RV RECEPTACLE

GRN

WHT

BLK

50 AMP

CIRCUIT

BLK

240 VOLT

50 AMP TWIST-LOCK RECEPTACLE RECEPTACLE

GRN GRN

WHT

RED

BLK

RED

WHT

50 AMP

CIRCUIT

BREAKER

240 VOLT

50 AMP

TWIST-LOCK

RED

BLK

RED

WHT

35

DC WIRING DIAGRAM

HOUR

VIO/YEL

BLK/WHT

VIO/YEL

RED

10 AMP

CIRCUIT

BREAKER

BLK

FUEL

PUMP

BLK/WHT

RED

GRY/BLU

GRY/VIO

OIL

WARNING

PRESSURE

SWITCH (N.C.)

WARNING

OVERHEAT

SWITCH (N.O.)

VI/YL

RD/YL

VI/YL

BLK/YEL

RED/WHT

CONTROL

RESISTANCE

BLK/YEL

GLOW PLUGS

RD/VI

STARTER SWITCH

SPLICE

RED/YEL

ORG/YEL

AUX SWITCH

MAIN BREAKER

BLU

BLK

VIO/WHT

VIO

BLK/WHT

N/O

COM

N/C

-

RELAY

+

TIME DELAY

12V BATTERY

E-STOP

SWITCH

RED

STARTER

BLK

RED/VIO

ALTERNATOR

WHT (PULL)

RED (HOLD)

SOLENOID

BLU (COM)

RED (PULL)

WHT (HOLD)

SOLENOID

BLU (COM)

ISUZU

36

MITSUBISHI

"TURN MAIN

BREAKER OFF"

WARNING LIGHT

90322_B_03.07.14

DC WIRING DIAGRAM - ELECTRIC WINCH OPTION

YL

WINCH 2

BL

5A

F2

BLK

CONTACTOR 2

BLK

WHT

UP

DOWN

SWITCH 2SWITCH 1

BK

RD

CONTACTOR 2

BL YL

RELAY 2

PROX. AUX

BK BN GN

87

VI

8586

BRN

BLK

87A

30

J

1

5

463

72

P

VIEWED FROM

WIRE INSERTION END

6 7532

6

5

413

27

BLU

BLK

BRN

VIEWED FROM

WIRE INSERTION END

LIFT

PROX. SWITCH 2

YL

WINCH 1

BL

5A

F1

BLK

DOWN

CONTACTOR 1

WHT

UP

BL YL

BK

RD

BK BN GN

87

RELAY 1

PROX. AUX

86 85

BRN

BLK

87A

VI/YL

BLK

RED

30

BLK

RED

-+

12 V

J2

P2

BATTERY

BLU

BLK

TILT

PROX. SWITCH 1

1

BRN

J1

P1

90463_B_07.16.14

37

DC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT

BLK

RED

-

+

12 V

BATTERY

BATTERY CHARGER

EDISON PLUG

BLU

BRN

YEL/GRN

16/3

BATTERY

CHARGER

HEATED FUEL FILTER

RD/BK

RD/WT

2

R

BK/WT

1

R

B

STARTER SWITCH

25A

FUSE

BK

8586

87

ACC

C

NCCOM

87A

RD/VI

SPLICE

BK

TO

GND

BAR

30

RD/BK

NO-

TIME

DELAY

+

TO CNTRL

PANEL START

SOL WIRE

TO

GND

BAR

TO MAIN

BREAKER AUX

OR/YL2

21

20A

SWITCH NC PIN

OR/YL1

ESTOP

RD/WT

BK/WT1

TO

GND

BAR

BK

RPM

SENSOR

WT

BK/WT

-

+

12 V

BATTERY

BK/WT2

43

GY

CIRCUIT

BREAKER

RD

POSITIVE AIR SHUTDOWN 6-20KW

BK/WT

FLOAT

SWITCH

LOW FUEL SHUTDOWN

SOLENOID

PASS

OPT

SW

RPM

PWR

GND

NCCOM

BK1

GND

TIME

+

SOL

PNK

DELAY

PASS

NO-

WT/VI

SPLICE

BATTERY

DISCONNECT

ALT CONFIG

MTB PIN 12

INTERIOR LIGHT BATTERY DISCONNECT

-

+

12 V

BATTERY

10A

FUSE

2

R

1

R

B

STARTER SWITCH

LIGHT

ACC

C

BK

WT

RD

38

90323_K_06.04.14

TRAILER LIGHTS WIRING DIAGRAM

AMBER

MARKER

LAMP

MARKER

LAMP

RED

RIGHT

TAIL/TURN

LAMP

BK

WT BN YL

PLUG

GN

TRAILER

BK

SPLICE

WT

BN

BK

SPADE

BK

SPADE

WT

RING

RD

SPLICE

GN

BK

WT

SPLICE

BK

LAMP

AMBER

MARKER

BN

WT

BN

SPADE

BK

RED

BN

WT

SPADE

BK

LAMP

MARKER

YL

SPADE

RDWTBK

LEFT

TAIL/TURN

LAMP

BN

WT

BK

SPADE

WT

90341_B_12.20.13

LAMP

PLATE

LICENSE

39

SERVICE LOG

OIL GRADE AND TYPE: ____________________________BRAND:___________________________________

COOLANT MIXTURE: ______________________________ BRAND:___________________________________

__________________________________________________________________________________________

40

NOTES

__________________________________________________________________________________________

41

__________________________________________________________________________________________

42

REV: L PART NO: 12685

11.17.14

Magnum MLT4150, MLT4200, MLT4200ICAN Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual