Magnum MLT4060KV Page 1 Operating Manual Download

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POWER PRODUCTS LLC

LIGHT TOWER

MLT4060MV • MLT4060KV

00121

MLT4080KV

OPERATING MANUAL

Summary of Contents for MLT4060KV

Page 1: ...Parts manuals available online www m p llc com POWER PRODUCTS LLC LIGHT TOWER MLT4060MV MLT4060KV 00121 MLT4080KV OPERATING MANUAL ...

Page 2: ...professional perform all electrical wiring and testing functions Any wiring should be in compliance with the National Electrical Code NEC state and local codes 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 m p llc com For technical or parts QUESTIONS ple...

Page 3: ...LATION OPTION 19 DERATING FOR ALTITUDE 19 WET STACKING 20 CONTROL PANEL RECEPTACLES 20 SHUTTING DOWN THE UNIT 20 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 KUBOTA ENGINE 26 WINCH USE OPERATION MAINTENANCE 27 JACK MAINTENANCE 27 TRAILER WHEEL BEARINGS 28 LOWER RADI...

Page 4: ...orspecificapplications DO NOT modify orusethis equipment foranyapplication 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 andcontrols Inexperiencedoperatorsshouldreceiveinstructionfromsomeone familiar withtheequipment before bei...

Page 5: ...r 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 flas...

Page 6: ...ing the unit 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 coupl...

Page 7: ... 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 Je...

Page 8: ... hazard keep open flames away from unit Read and understand the supplied operator s manual before operating unit Ultraviolet radiation hazard operate only with lens intact Use clean diesel fuel only Unit electrical ground Anchor tie down point Lift here only Asphyxiation hazard operate in well ventilated area Dangerous voltage may be present Crush hazard keep body parts clear of this area Burn sca...

Page 9: ...VA 6 0 6 0 6 0 6 0 Output Voltage V 120 240 single phase 120 240 single phase Output Amperes 120V 240V A 50 25 50 25 Frequency Hz 60 60 Power Factor 1 1Ø 1 1Ø Weights Dry Weight lbs kg 1759 798 1779 807 Operating Weight lbs kg 2162 981 2182 990 Capacities Fuel Tank Volume gal L 56 212 56 212 Usable Fuel Volume gal L 56 212 56 212 Coolant incl engine qt L 4 5 4 3 4 8 4 5 Oil incl filter qt L 3 8 3 ...

Page 10: ...kW kVA 8 0 8 0 Output Voltage V 120 240 single phase Output Amperes 120V 240V A 66 33 Frequency Hz 60 Power Factor 1 1Ø Weights Dry Weight lbs kg 1785 810 Operating Weight lbs kg 2188 992 Capacities Fuel Tank Volume gal L 56 212 Usable Fuel Volume gal L 56 212 Coolant incl engine qt L 4 8 4 5 Oil incl filter qt L 5 4 5 1 Maximum Run Time hrs 80 Lighting Lighting Type Metal Halide Ballast Type Coil...

Page 11: ...11 UNIT DIMENSIONS Specifications are subject to change without notice A B C D E MLT4060MV KV MLT4080KV 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 D A B E C 00213 ...

Page 12: ...g TIRE AND LOADING INFORMATION RENSEIGNEMENTS SUR LES PNEUS ET LE CHARGEMENT SEE OWNER S MANUAL FOR ADDITIONAL INFORMATION VOIR LE MANUEL DE L USAGER POUR PLUS DE RENSEIGNEMENTS MANUFACTURED BY FABRIQUE PAR Magnum Power Products LLC DATE 00 0000 GVWR PNBV 000KG 0000LBS COLD INF PRESS PRESS DE V I N N I V 00000000000000000 TYPE TRAILER MODEL XXX000 GAWR PNBE TIRE PNEU RIM JANTE GONF A FROID KPA PSI...

Page 13: ...13 COMPONENT LOCATIONS LEFT SIDE RIGHT SIDE Engine Exhaust Control Box Central Lift Point Mast Switch Forklift Pockets Battery Engine Access Fuel Fill Outriggers Mast Rotation Knob Radiator Access 00109 ...

Page 14: ...rements 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 90 so the jack pad is facing down and the spring loaded pin snaps back into place 6 Pull the locking pin on the rear jack F and rotate the jack 90 until the spring loaded pin snaps back into place Turn t...

Page 15: ...lectrocution Repair or replace a damaged cord 3 Press and hold the winch control toggle switch B 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 s...

Page 16: ...one 120V 20A GFCI receptacle to supply power for accessories connected to thegeneratorwhenthe engine isrunning and themaincircuit breakeris switched ON I 9 240V TWIST LOCK RECEPTACLE This 240V 30A receptacle supplies power for accessories connected to the generator when the engine is running and the main circuit breaker is switched to the ON I position 10 120V BREAKER This 120V 20A circuit breaker...

Page 17: ... to the generator when the engine is running and the main circuit breaker is ON I 9 240V TWIST LOCK RECEPTACLE This 240V 30A receptacle supplies power for accessories connected to the generator when the engine is running and both the main circuit breaker and 240V breaker are switched to the ON I position 10 120V BREAKERS These 120V 20A circuit breakers are supplied for the 120V GFCI duplex recepta...

Page 18: ...e in the OFF O position Note When the red TURN MAIN BREAKER OFF light is illuminated the main circuit breaker must be turned OFF O 2 Turn the key on the Engine Start switch to the left GLOW PLUG position and hold the key in place for five seconds or until the glow plug indicator turns red Kubota units do not have a glow plug indicator As soon as it is glowing Turn the key to the right START positi...

Page 19: ...e 29 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...

Page 20: ...overload the generator and cause the main circuit breaker to trip Should the breaker trip switch off the lights remove some of the load to the receptacles and wait 10 minutes for the bulbs to cool before turning them back on With all of the lights off the full generator output may be used with the optional 240V twist lock receptacle SHUTTING DOWN THE UNIT Check with personnel using power supplied ...

Page 21: ...If the generator is not operational and the batteries do not have enough power to lower the mast it may be necessary to lower the mast manually Note 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 MANUALLY LOWERING THE MAST Do not use this procedure unless it is absolutel...

Page 22: ...ck 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 ...

Page 23: ...t capacity For approximate weights refer to Specifications beginning on page 9 2 Always remain aware of people and objects around the unit while moving 3 Use the upper or lower forklift pockets with care 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 Lower Forkl...

Page 24: ...ch 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 goodcondition andarecentered on each pulley DO NOT use a cable that is kinked or starting to unravel Check the wheel lugs Refer to Towing the Unit on page 22 Check coolant levels Refer to the engine operator s manual whe...

Page 25: ...nterval 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 Item Daily 50 Hours 250 Hours 400 Hours 500 Hours 1000 Hours As Required Check Oil Level Check Coolant Level Check Fuel Level Check Tire Pressure Check All Electrical Connections Inspect Radi...

Page 26: ...d oil filter after the initial 50 hours of operation then at the appropriate interval thereafter Replace the air cleaner element yearly or after six cleanings whichever occurs first Item Daily 50 Hours 100 Hours 200 Hours 400 Hours 500 Hours 1 Year Check Oil Level Check Coolant Level Check Fuel Level Check Tire Pressure Check All Electrical Connections Inspect Radiator Fins For Debris Clean As Req...

Page 27: ...HEDULE 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 compo...

Page 28: ... 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 engin...

Page 29: ...ick 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 l...

Page 30: ...30 MAST LIGHT CONNECTIONS 1 3 2 4 2 1 4 3 MAST JUNCTION BOX WIRING 4 LIGHT MAST LIGHT CONNECTIONS 4 LIGHT 00175 ...

Page 31: ...D BAR MAIN 20A CB6 30A CB7 GFCI 15 A CB4 15 A CB3 15 A CB2 15 A CB1 RED RED BLK BLK BLK BLK WHT GRN RED YEL RED BLK BLU WHT YEL RED BLK YEL RED BLK YEL RED BLK YEL RED BLK BLU BLK RED GRY BLU BLK RED GRY RED RED RED RED RED RED GRY GRY BLK BLK BLK BLK BLK BLK BLU BLU BLU BLK RED YEL RED BLK BLK RED RED BLK RED BLK RED BLK RED BLK CAP 2 CAP 1 CAP 3 CAP 4 TRANSFORMER 1 TRANSFORMER 2 TRANSFORMER 3 TR...

Page 32: ...LK WHT RED BLK FUEL PUMP 10 AMP CIRCUIT BREAKER OIL PRESSURE WARNING SWITCH N C SWITCH N O WARNING OVERHEAT 12V BATTERY STARTER RELAY TIME DELAY GRY BLU GRY VIO VI YL RED BLK CONTROL RESISTANCE BLK YEL GLOW PLUGS AUX SWITCH MAIN BREAKER RD VI ALTERNATOR WARNING LIGHT TURN MAIN BREAKER OFF BLK WHT BLK RED YEL ORG YEL RD VI RED VIO N C N O COM 90340_C_ 04 23 13 ...

Page 33: ... YEL BLK WHT BLK WHT RED BLK FUEL PUMP 10 AMP CIRCUIT BREAKER OIL PRESSURE WARNING SWITCH N C SWITCH N O WARNING OVERHEAT 12V BATTERY STARTER RELAY TIME DELAY GRY BLU GRY VIO RED RED BLK BLK YEL GLOW PLUGS AUX SWITCH MAIN BREAKER VIO WHT ALTERNATOR WARNING LIGHT TURN MAIN BREAKER OFF BLK WHT BLK RED YEL ORG YEL BLU RED VIO N C N O COM ...

Page 34: ...7 29 13 30 85 86 87A 87 PROX SWITCH 2 WINCH PROX RELAY BK BK YL BL RD WT VI YL DOWN UP CONTACTOR 1 SWITCH 1 BATTERY TO B OF KEY SWITCH GN BN BK BK RD BL YL 30 85 86 87A 87 PROX RELAY PROX SWITCH 1 BN UP DOWN BN BK BL VI BK BL BN DOWN UP BK BK 1 2 ...

Page 35: ...MTB PIN 12 ALT CONFIG B ACC R B C R 1 2 R BK WT RPM SENSOR PASS GND PWR RPM SW OPT GND SOL CIRCUIT BREAKER 20A BATTERY 12 V ESTOP SOLENOID PASS RD WT BK SPLICE SPLICE RD RD WT BK WT1 PNK BK1 BK BK WT BK WT2 GY TO GND BAR TO GND BAR OR YL1 OR YL2 TO CNTRL PANEL START SOL WIRE TO MAIN BREAKER AUX SWITCH NC PIN 4 3 2 1 90323_I_11 18 13 BK WT RD BK BK STARTER SWITCH 30 85 86 87A 87 FUSE RD WT RD VI TO...

Page 36: ...AIL TURN LAMP LAMP PLATE LICENSE MARKER LAMP RED BK BK BK BK RD WT BK SPLICE SPLICE SPADE SPADE LAMP TAIL TURN LEFT RD WT BK SPADE YL BN WT SPADE SPADE WT BK BN WT SPLICE GN RING MARKER LAMP AMBER MARKER LAMP RED BK BK BK BK SPLICE SPLICE SPADE SPADE BN WT WT WT BN BN 90341_B_12 20 13 ...

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