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32

AC WIRING DIAGRAM 

1

2

3

1

2

3

1

2

3

1

2

3

2

3

1

4

2

3

1

4

BLU

BLK

BLU

BLK

GR

Y

RED

GR

Y

RED

GEN

MAST

 CABLE

MAIN 

CIRCUIT

 

BREAKER

BK

RD

RD

BK

BK

RD

BL

GY

BL

BK

RD

30A

LIGHT

 SWITCHES

15A

1

5A

15A

1

5A

L1

L2

TRANSFORMERS

12

4

3

CAP

 1

CAP

 2

C

AP

 3

CAP

 4

LED BOARD

YL

BL

WT

RD

BK

T

O

 RECEPT

ACLES

BK

BL

RD

YL

WT/BK

WT

GN

RD

BK

BL

GY

BL

BL

BL

BK

RD

BK

RD

BK

RD

BK

RD

BK

RD

12

11

10

9

8

7

6

5

4

3

2

1

1

2

3

4

5

6

7

8

9

10

11

12

1

GN

WT

3

GN

WT

BK

2

GN

WT

BK

4

GN

WT

BK

BK

90454_B_06.21.14

Summary of Contents for MLT4150

Page 1: ...Parts manuals available online www magnumpower com LIGHT TOWER 01129 MLT4150 MLT4200 MLT4200ICAN OPERATING MANUAL ...

Page 2: ...essional 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 QUEST...

Page 3: ...T 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...

Page 4: ...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 andcontrols Inexperiencedoperatorsshouldreceiveinstructionfromsomeonefamiliarwiththeequipment before being allowed to operate or set up the unit T...

Page 5: ...annot 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 gasol...

Page 6: ...ding 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...

Page 7: ... 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 Jerse...

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: ... 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 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...

Page 10: ... 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 Regulat...

Page 11: ...11 UNIT DIMENSIONS Specifications are subject to change without notice A B C D E MLT4150 MLT4200 MLT4200ICAN 170 in 4 32 m 70 in 1 78 m 30 ft 9 14 m 68 in 1 73 m 140 in 3 56 m E C 00209 D B A ...

Page 12: ...ILER MODEL XXX000 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 SECURI...

Page 13: ...MPONENT LOCATIONS LEFT SIDE RIGHT SIDE Mast Rotation Knob Central Lift Point Forklift Pockets Engine Exhaust Emergency Stop Switch Control Box Battery Engine Access Fuel Fill Outriggers Radiator Access 00105 ...

Page 14: ...se 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 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 ja...

Page 15: ...maged 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 mas...

Page 16: ...ch 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 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 e...

Page 17: ...ight 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 NEUTRAL BONDED TO FRAME BALLAST INDICATOR LIGHTS MAST LIGHT SWITCHES I O I O I O I O GLOW ...

Page 18: ... 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 d...

Page 19: ...ture 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...

Page 20: ... 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 ...

Page 21: ...tation 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 equi...

Page 22: ...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...

Page 23: ...place 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 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 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 11 M...

Page 24: ...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 o...

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: ...zed dealer in your area Item Daily 250 Hours 500 Hours 1000 Hours 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 ...

Page 27: ...ngs 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 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 t...

Page 28: ...LS 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 h...

Page 29: ...ATOR 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 coo...

Page 30: ...uick 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 ...

Page 31: ...31 MAST LIGHT CONNECTIONS 1 3 2 4 2 1 4 3 MAST JUNCTION BOX WIRING 4 LIGHT MAST LIGHT CONNECTIONS 4 LIGHT 00175 ...

Page 32: ...BK BK RD BL GY BL BK RD 30A LIGHT SWITCHES 15A 15A 15A 15A L1 L2 TRANSFORMERS 1 2 4 3 CAP 1 CAP 2 CAP 3 CAP 4 LED BOARD YL BL WT RD BK TO RECEPTACLES BK BL RD YL WT BK WT GN RD BK BL GY BL BL BL BK RD BK RD BK RD BK RD BK RD 12 11 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 1 GN WT 3 GN WT BK 2 GN WT BK 4 GN WT BK BK 90454_B_06 21 14 ...

Page 33: ...TO GROUND TO NEUTRAL TO MAIN BREAKER RED BLK BLK RED WHT WHT GRN GRN GRN WHT RED BLK RED RED BLK BLK RED RED RED RED BLK BLK BLK BLK GRN WHT GRN GRN GRN WHT WHT WHT 240 VOLT 50 AMP TWIST LOCK RECEPTACLE RECEPTACLE 240 VOLT 50 AMP TWIST LOCK 30 AMP CIRCUIT BREAKER 30 AMP CIRCUIT BREAKER BREAKER CIRCUIT 50 AMP BREAKER CIRCUIT 50 AMP RED RED 240 VOLT 30 AMP TWIST LOCK RECEPTACLE 90317_ORG_07 06 11 ...

Page 34: ...I OUTLET 20 AMP G F I OUTLET 30 AMP CIRCUIT BREAKER 30 AMP CIRCUIT BREAKER 30 AMP CIRCUIT BREAKER 50 AMP CIRCUIT BREAKER TO GROUND TO NEUTRAL TO MAIN BREAKER RED BLK BLK RED WHT WHT GRN GRN GRN WHT RED BLK RED RED RED RED RED RED RED RED BLK BLK BLK BLK GRN WHT GRN GRN GRN WHT WHT WHT BLK BLK BLK BLK 240 VOLT 50 AMP TWIST LOCK RECEPTACLE 240 VOLT 30 AMP TWIST LOCK RECEPTACLE 240 VOLT 30 AMP TWIST ...

Page 35: ...T TO GROUND TO NEUTRAL TO MAIN BREAKER RED BLK BLK RED WHT WHT GRN GRN GRN WHT RED BLK RED RED BLK BLK RED RED RED RED BLK BLK BLK BLK GRN WHT GRN GRN GRN WHT WHT WHT 240 VOLT 30 AMP TWIST LOCK RECEPTACLE BLK BLK RED RED 240 VOLT 30 AMP TWIST LOCK RECEPTACLE 240 VOLT 30 AMP TWIST LOCK RECEPTACLE 240 VOLT 30 AMP TWIST LOCK RECEPTACLE 30 AMP CIRCUIT BREAKER 30 AMP CIRCUIT BREAKER 30 AMP CIRCUIT BREA...

Page 36: ...URE WARNING SWITCH N C SWITCH N O WARNING OVERHEAT 12V BATTERY STARTER E STOP SWITCH RELAY TIME DELAY GRY BLU GRY VIO RED RED BLK CONTROL RESISTANCE BLK YEL GLOW PLUGS AUX SWITCH MAIN BREAKER VIO WHT VIO ALTERNATOR WARNING LIGHT TURN MAIN BREAKER OFF BLK WHT BLK RED YEL ORG YEL BLU RED VIO N C N O COM ISUZU RED PULL WHT HOLD BLU COM SOLENOID MITSUBISHI RD YL VI YL RD VI SPLICE 90322_B_03 07 14 ...

Page 37: ... 2 PROX AUX RELAY 2 BLK BLK YL BL WHT BLK BRN BRN BLU BLK VI DOWN UP 12 V BATTERY RED BLK RED BLK CONTACTOR 2 SWITCH 2 SWITCH 1 BL YL RD BK BK BN GN BL YL BK RD BK BN GN 6 7 5 3 2 1 J1 P1 PROX SWITCH 2 PROX SWITCH 1 J2 P2 5A F1 5A F2 7 2 5 4 6 3 1 J VIEWED FROM WIRE INSERTION END 2 7 5 4 1 3 6 P VIEWED FROM WIRE INSERTION END CONTACTOR 1 CONTACTOR 2 90463_B_07 16 14 ...

Page 38: ...I TO GND BAR 25A RD BK 10A MTB PIN 12 ALT CONFIG POSITIVE AIR SHUTDOWN 6 20KW 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 TIME DELAY NC COM NO BK SPLICE TIME DELAY NC COM NO BK...

Page 39: ...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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Page 44: ...REV L PART NO 12685 11 17 14 ...

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