manual - planta magnun

7/25/2019 Manual - Planta Magnun

1/48

GNUM

PRODUCTS LLC

NIGHTBUSTER LIGHT TOWER

MODELS MLT3060 & MLT3080

OPERATORS MANUAL / PARTS OOK

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2/48

This manual providas information and procedures to safely operata and maintain tha light tower

and ganerator. For your own safety and protection from physical injury, carafully read, undar-

stand, and observa the safety instructions dascribed in this manual. TH INFORMATlON CON-

TAINED

IN

THIS MANUAL WAS BASED ON MACHINES

IN

PRODUCTION T TH TIME OF

PUBLlCATION. MAGNUM PRODUCTS LLC RESERVES THE RIGHT

TO

CHANGE ANY POR-

TION OF THIS INFORMATION WITHOUT NOTICE.

n angina operators manual was supplied with the machine at the time of its shipment from the

factory. The manual provides detailed operation and maintenance procedures far the angina.

Additional copies of this manual

are

available from the engina manufacturer.

M GNUM

PRODUCTS LLC

215

POWER

ORIVE

BERLlN, WI 54923

PHONE: 920-361-4442

FAX: 920-361-4416

TOLL FREE: 1-800-926-9768

www.m-p-Ilc.com

Engine Make:

_

Engine Serial

# _

Engine Model

#

Generator Make: _

Generator Model

#

Generator Serial

#

Unit Model

# _

Unit Serial

#

2
http:///reader/full/www.m-p-Ilc.comhttp:///reader/full/www.m-p-Ilc.com


3/48

T BLE O CONTENTS

TABLE OF CONTENTS

SAFETY NOTES

UNIT SERIAL PLATE

OPERATING SAFETY

ENGINE SAFETY

TOWING SAFETY

SERVICE SAFETY

SPECIFICATIONS

LlGHT TOWER SET UP

RAISING THE TOWER

MAIN

CONTROL PANEL

ENGINE STARTING ANO OPERATION

AUTOMATIC SHUTOOWN

LlGHT OPERATION

AUXILlARY OUTLETS

OERATING FOR ALTITUOE

SHUTTING DOWN

LOWERING THE TOWER

TOWING THE TRAILER

LlFTING THE TRAILER

TROUBLESHOOTING THE LlGHTS

OAILY INSPECTION ANO MAINTENANCE

DECAL LOCATIONS

MANUAL WINCH MAST

ASSEMBlY

FRAME ANO COMPONENTS

METAL ENCLOSURE COMPONENTS

CATERPILLAR ENGINE ANO GENERATOR

MITSUBISHI ENGINE ANO GENERATOR

CONTROL PANELASSEMBlY

CONTROL BOX ASSEMBLY

HIGH PRESSURE SOOIUM LlGHT ASSEMBLY

METAL HALlOE LlGHT ASSEMBLY

QUICK OISCONNECT MAST JUNCTION BOX ASSEMBLY

MAST JUNCTION BOXASSEMBLY

METAL HALlDE BALLAST

BOX

ASSEMBLY

HIGH PRESSURE SOOIUM BALLAST BOXASSEMBLY

GENERATOR ASSEMBLY 6kW

AC CIRCUIT WIRING DIAGRAMS

OC

CIRCUIT WIRING OIAGRAMS

TRAILER LlGHTS WIRING DIAGRAM

JUNCTION BOX WIRING DIAGRAMS

PAGE3

PAGE4

PAGE4

PAGE5

PAGE5

PAGE6

PAGE6

PAGE7

PAGE8

PAGES 9 10

PAGE

PAGE 12

PAGE 12

PAGE 13

PAGE 13

PAGE 14

PAGE 14

PAGE 14

PAGE 15

PAGE 15

PAGE 16

PAGE 17

PAGES 8 2

PAGES22 23

PAGES24 25

PAGES26 27

PAGES28 29

PAGES 30

3

PAGES32

33

PAGE34

PAGE35

PAGE36

PAGE 37

PAGE38

PAGE39

PAGE40

PAGE41

PAGES42 43

PAGES4445

PAGE46

PAGE47

3


4/48

SAFETY NOTES

Ths manual contains NOTES, CAUTIONS and WARNINGS which must be followed to prevent !he

possibility 1 improper service, damage

lo

!he equipment. or personal injury. The following lormatting

options will apply when calling the readers attention to the NOTES, CAUTIONS and WARNINGS

Notes: Notes contain additional information important to a procedure. The notes called out in this manual

will be included in the regular texl body but the word "Note" will be in BOLO text and !he note will be written

in italics lo make them more visible. For example: Note

Check the engine o/level before startng

CAUTlON: Cautions previde information important to prevent errors which eould damage Ihe equipment.

The cautions called out in Ihis manual will be in BOLO text, in a separate paragraph

or

sentenee trom Ihe

regular texl body. For example:

CAUTION! Always switch all circuit breakers to "OFF" to preven

the

starting of

the generator

under

load.

WARNINGS: Warnings describe conditions

or

practices which could lead to serious personal injury or death

to the aperator or olhers around the equipment. Warnings called out in this manual will

be

in a separate

paragraph, centered and surrounded by a black border, wilh all informalion in BOLO texto For

example:

WARNINGI

Only a

qualified

electrician

may servica

or make

connectione

to Ihe generator. Lethal voltage ie present

at

the connection

lugs when

the

generator is

runningl

lINIT SERIAL PLATE LOCATION

I ~

= := !

L ~ ::=J

S i C i l 1 ~ :

~ - - _ . - -

.J

[ I i i ~ - - ,

~ = J

li!!L -=:J

\

4


5/48

OPER TlNG S FETY

Before using the light lower

be sure

you

read

and understand

all

inslructions! Equipment aparated improperly

ar by untrained parsonnal can be dangerous! Read

the

operating instructions and familiariza yourself with #le

locatian and properuseo all instruments

and

controls. Inexperienced oparators should receive instruction from

somaone familiar

with

the equipment before being allowed

to

operate or sel up Ihe machine.

The area immediataly surrounding

the

light tower should

be

elean,

neat,

and free of debrs.

Posion and operate light towar on a firm, leval surface.

NEVER

start a unit in

need

of repair.

Lowar tower

when

not

in use,

or if

high

winds or electrical slorms

are

expected

in

Ihe

area.

Make certain light !ower

is well

grounded and securely faslened to a good earthen ground.

The tower extends up to

30 n

(gm).

Make

sure

area

aboye trailer is

open

and clear of overhead wires and

obstructions.

Bulbs becoma extramaly

ho!

is usa! Allow

bulb and

light fixture to

cool

10-15 minutes before handling.

Kaap area behind trailer clear of people while raising and lowering masl! NEVER raise, lower or turn

mas!

whila unit is oparating!

Trailer mus!

be

leveled

and

outriggers extended before

raising

tower. Outriggers must

remain

axtended

while tower is up.

If lor any reason any part

of

mast hangs up or

winch

cable develops slack while raising ar lawering tawer,

STOP immadiately! Contact

an

authorized service representative.

NEVER remove safety

pin

or

pull

mast

locking

pin

while tower is

up!

NEVER use tower if insulation on electrical

cerd is

cut or

worn

through.

NEVER operate lights without protective lans

cever in

place orwith a

lens

cover thal is cracked ar damaged!

NEVER adjust mast while unit

is

aperating.

ENGINE S FETY

Internal combustion engines present special hazards durng operation

and

fueling! Failure

to

follow the safety

guidelines described below

could

result

in

severe injury or death. Also

read

and follow all safety wamings

described in the

Engine

Operator's Manual. A copy

of

this manual was supplied with unit when il was shipped

from

the

factory.

DO NOT

run engine

indoors or

in

an

area

with poor ventilation unless exhaust hoses

are

used.

DO NOT fill

fue!

tank near

an

opan flame, while smoking, or while

engine

is

running.

DO NOT fill tank

in

an

enelosed

area

with

poor ventilation.

DO NOT touch

or

lean against hat exhaust

pipes

or engine cylinder.

DO NOT operate with

the fuel

tank

cap

loose

or

missing.

DO NOT remove engine coolant cap while engine is ho!.

DO NOT elean

air

filter

with

gasoline

or

other types o low flash point solvents.

Keep area

around

exhaust pipes and air ducts

free

of

debrs to reduce

the chance of

an

accidental

fire.

Shut

the

engine

down

if

any

of

the following conditions

exist

during operation:

A.

Noticeable changa

in

engine speed.

B. Loss of electrical

output.

C.

Equipment connected to the generator overheats.

D. $parking occurs.

E. Englna misfires or Ihere ls excessive engineJgenerator vibralion.

5


6/48

TOWING S FETY

Towing a Irailer requires care! 80th the !railer and vehicle mus be in goOO condition and securely fastened to

each other to reduce the possibility

of

an accident. Also, some slates require that large trailers be registtlred

and licensed. Contactyour

local Departrnent

of

Transportation office

to

check on license requirements for your

particular unit.

Check tIlat the hilch and coupling on the lowing vehicle are rated equal lO or greater Ihan, the trailer's 'gross

vehicle weight rating' (GVWR). Check tires on traifer for Iread wear. inllation, and condition.

Inspect the hitch and coupling

for

wear

or

damage.

DO

NOT

tow

trailer

using

defective parts!

Make sure the traller hitch and

the

coupling are compatible.

Make

sure

the

coupling

is

securely fastened

lo the vehicle.

Connectsafetychains in a crossing pattem underthe tongue and attach the brake away cable TO THE REAR

BUMPER OF THE TOWING VEHICLE.

Make

sure directional and brake lights on Ihe trailer are eonnected and working properly.

Check that

lug

nuts holding wheels are tight and tIlal none are missing.

Maximum recommended speed

lor

highway lowing is 45 mph. Reeommended off-road towing speed is nol

lo exceed 1 mph or less depending on lerrain.

When towing, mainlain extra space between vehicles and avoid 50ft shoulders, curbs

and

sudden

lane

changes. If you have not pulled a trailer before, practice tuming, stopping, and backing up in an area away

from heavy traffic.

A film 01 grease on the coupler will extend coupler life and eliminate squeaking. Wipe the coupler clean and

apply fresh grease each

time

the trailer is towed.

REPORTING TR llER S FETY DEFECTS

I you believe your traller

has

a delect whieh eould cause a crash or could cause injury or death. you should

immediately inlorm Ihe National Highway Traffic Salety Adminislration (NHTSA) in addition

lo

notifying

Magnum Products LLC. 1I NHTSA reeeives similar eomplaints.

il

may open an investigalion; and if i l finds

that a safety defeet exists in a group

01

vehicles

it

may order a recall and remedy eampaign. However.

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

To

contact NHTSA. you

may

either call the Auto Safety Hotline toll-Iree

at

1-888-327-4236 or by lax at:

(202)-366-7882.

Addilional conlact inlormaton can be lound al: www.nhtsa.dot.gov.

SERVICE S FETY

This unit uses high voltage circuits capable 01 causing serious injury or dealh. Only a qualilied electrician

should troubleshoot or repair electrical problems occuring in this equipment.

Belore servicing lighl tower. make sure engine start switch is turned lo OFF. circuit breakers are open (off)

and the negative terminal on

the

battery is disconnected. NEVER perform even routine service (oil!filter

changes. cleaning. etc.) unless all electrical components are shut down.

NEVER

allow

waterto

accumulate around the base

ofthe

lighttower se!.

Ifwaler is

presento DO

NOT

service!

NEVER

service electrical compenents

il

cloth ing or skin s wet. I the unt is stored outside, check tIle engine

and generator

lor any

mosture and dry the

unit

before use.

NEVER wash the uni with a

power

washer

or

high pressure hose.

Open main circuit breaker belore disconnecting battery cables.

Keep hands, leet,

and

loase clothing away from moving parts on generator and engine.

Replace all guards and salety devices immedialely aftar servicing.

Replace all missing

and

hard-to-read labels. Labels provide importa

ni

operatng instruclions and

wam of

dangers and hazards.

Make

sure slings, chains. hooks, ramps, jacks, and other types 01 lifting devices are attached securely and

have enough weight-bearing capacity to lift or hold tIle equipment salely. Always remain aware

01

the

pesilion

01

other people around you when lifting the equipment.

6
http:///reader/full/www.nhtsa.dot.govhttp:///reader/full/www.nhtsa.dot.gov


7/48

SPECIFlC noNS

Engine manufacturer

Engine model

Enginetype

Engine horsepower (standby)

Engine horsepower (primed)

Fuel tank capacity

Fue! consumption

Engine manufacturer

Engine model

Enginetype

Engine horsepower (primad)

Fuel tank capacity

Fuel consumption

Generator manufacturer

Generator modal

Generator output

kW)

Generalor output (kVA)

Generator frequency

Generator output voltage

Generator output (amperes)

Generator power factor

Generator insulation

Ughting type

Ballast type

Lumens

Coverage (approximate)

Maximum height of tower

Length

wilh

mas! stowed

Width

Width with outriggers extended

Height

Weight with fual

Mitsubishi

L3E-W26IML

Diesel, 3-cyl, liquid coolad 4-stroke

12.7

hp

(9.3 Kw) @1800RPM

10.9

hp

(8.0 Kw) @1800 RPM

30 gal. (113.7

L)

.5 gph (1.89

Lph)

Caterpillar

3013

Diesel, 3-cyl, liquid cooled 4-stroke

31.5 hp

(23.5 Kw) @ 2800 rpm

30 gal. (113.7 L)

.5

gph

(1.89

Lph)

Maralhon Electric

332CSA5214

6.0

6.0

6 Hz

1201240V,

single phase

50-25

1.0

Class p

Metal halide or high pressure sodium

Coil

&

core

440,000

5-7 acres (20,235-28,329 sq meters)

30 ft. (9.14

m)

170 in. (452 cm)

48 in. (162.6 cm)

98 in. (345.4 cm)

68 in. (177.8 cm)

1850 lbs (839

kg)

7


8/48

REAR

JACK

lOCKTHE

~ L T ; : ; R A I L E R

WHEElS

LlGHT TOWER SET UP

GROUNDING

STUD

TONGUE

JACK

1. For maximum light coverage loeate tower at ground level

or

in a spot higher han the area being iUuminated

by

the

lamps.

WARNING I

The tower extends

up to 30 ft 9.14

m).

Make

sure area aboye

the

traller

Is

open

and

clear

of

overhead wlres and obstructlons.

2. Place

the

traller

onlirm

ground Ihal

is

relatively flat. This will make

it

easier

lo

evelthe

Iower. Blockthe wheels

on he trailer

lo keep

it from moving.

3. Connecl a good earthen ground lo the grounding slud on

the

lrame 01 Ihe lrailer near Ihe Irailer tongue.

4. Pull

the

loeking pin on he tongue

jack

and rolale

it

90 untillhe

spring loaded pin snaps

back

into place.

Turn

the

jack han die cloekwise to raise he traller tongue off 01 the towlng vehicle.

5. Pull

the

locking pins

on

the outrlggers and extend each outrigger until the spring loaded locking pin snaps

back into place (A). Pull the loeking pin on the outrigger jacks and rolale them until the

jack

pads are lacing

clown and the spring loaded pin snaps back into place (B).

6. Pull the loeking pin on Ihe rear jack

and

rOlale

il 90

unlil he spring loaded pin snaps back inlo place. Turn

he jack handle cloekwise 10 slart leveling Ihe traller. Adjusl all four jacks by lurning Iheir handles cloekwise

until

they

are firrnly in contact with

the

ground

and

he trailer Is as level as possible

(e).

7. Remove the masl cradle locking pin (D).

e

8


9/48

RAISING

THE

TOWER

MAST

CABLE

roNGUE

WlNCH

JUNCTION BOX

MAST

W I N C H I ~ ~ J ~ ~ ~ ~

MAST

LOCK

LlGHT

AOJUSTMENT

HARDWARE

1. Betore raising!he lower t may be necessary to adjust the lamps. The lamps may be adjusted up. down, left

or

right

by

ioosening

the

nuts and bolts on

the

lamp fixtures and aiming them in the desired direction. TIghten

the hardware completely and make sure the lamps are connected to the junction box.

WARNING

he

trailer must

be

leveled with the outriggers extended before ralslng the

tower. The outrlggers must remaln extended

while

the

tower

Is up. Failure

to

level

the

traller

or

extend the outrlggers wlll severly reduce the stability

of

the

unlt

and could allow

the

tower

to

tip and fall.

3. Check both sets 1 cables lor excessive wear or damage. Make sure the cables are properly centered in

each pulley.

4.

Check

the

electrical coil cord

t r

damage.

WARNING

Do nol start the unit II the insulation on the eleclrieal eor Is cut or worn

through. Bare wires In contact with

the

mas!

or

frame may energize the

traller and cause electrocution. Repair

or

replaee

cardo

5. Remove the safety pin from the mast lock. Using

the

handle for!he tangue mounted winch (E), raise

the

mast until it

Is

vertical and the tab

on

the mast

is

positioned into the mast lock. The mast lock

should

snap

into place automatically. Secure

lhe

lock with the

safety pin

(F).

9

E F


10/48

R ISING TH TOWER (continued)

6. Afterthe Mas! s up and locked into place, use the winch on the mast

G) to extend the tower

lo

the desired heighl. Extend the mast

slowly, making sure tha! Ihe electrical cord is pulling Ireely Irom

the storage tube. 11 lor any reason, the cable begins to develop

slack or any 1 the lower sections gets stuck, STOP IMMEDI-

ATELY and contact an authorized service center. DO

NOT

EXTENO THE

MAST

BEVOND THE COLOREO MARKON THE

MAST TUBE (H).

7. The mast can

be

rotated by releasing the locking knob al the

bollom 01 the mast 1). Turn the mast until the lights face in the

desired direclion and then tighten the knob.

WARNING!

Never raisa

or lower

the

mast

while the unit

is

operating!

Never remove the safety pin

or mast

lock

while

the

tower

is up Releasing Ihe lock will cause Ihe mast lo fall.

I

10


11/48

1. M IN

CIRCUIT BREAKER (30A). This breaker will disconnecl power lo Ihe lights and auxiliary outlels.

II will also disable

Ihe

starting circuil il engine slarting

is

attempled

when Ihe main breaker

is

on.

2. INDIVIDUAL CIRCUIT BREAKERS. One breaker is supplied lor each light.

3. BALLAST INDICATOR LlGHTS. Indicates power from Ihe ballast lo each lght.

4.

OUTlET CIRCUIT BREAKER. This breaker is suppled tor the standard 120V GFCI outlet.

5.

AUXIUARV OUTLETS. These supply power lor accessories connected to Ihe generator when the

engine is running and the main circuit breaker is swilched to

Ihe

on

1

posi ion.

The 120V GFCI outlel is standard. Ihe 240V twis lock is optional.

6 ENGINE STARTlNG SWITCH. Keyed switch operates glow plugs. starts and stops engine.

7. ENGINE

GLOW PLUG

INDICATOR. Indicates operation

01

he engine glow plugs.

8. ENGINE

HOUR

METER. Keeps track 01 engine hours

lor

service.

9.

CIRCUIT BREAKER INDICATOR LlGHT. This light indicates ha the main circul breaker mus

be

opened (switched off) before starting Ihe engine.


12/48

ENGINE STARTING

AND

OPERATlON

1.

Check angine oil, fuel

and

coolant levals. Note:

/f tIle engine

was

run out

of fuelor

the fuel tank was

drained, it

may

be necessaty

to b/eed

the fue/lines. Refer

to

tIle engine operation

manual

supplied witll

the un/.

2. Check tha condition 01 the electrical cord on the Inslde 01 the unit.

WARNINGI

Do not start the

unlt If

the Insulation

on

the electrical cor

is

cut

or

worn

through. Bare wlres In contact with the mast or frame may energize the

trailer and cause electrocuton. Repar or replace cord.

3. Check tha

he

main circuit breaker and individual circuit breakers for each 01 he lights is in the

off "O" positlon.

Note: /f

tha red light on the control panel TURN MAIN BREAKER OFF

s

lluminated when the

key

is tumed to the

STARr

postion, the breaker is c/osed (switched on).

ARNINGI

NEVER START THE ENGINE

WITH

ANY

OF

THE

CIRCUIT BREAKERS SWITCHED ONI Any load on

the generator during 8tart up will cause severe

damage or destroy the generator

4.

Tum

the key on he engine start switch to the left "GLOW PLUG" positlon and hold he key in place until

the glow plug indicator tums red. As seon as It's glowing tum Ihe key to the right

lo

tha "START' pesltlon

and hold It until tha angina cranks and starts running. Ralease the key, it will moya to the "RUN"

position.

ACTIVATE GLOW PLUGS

CRANK

ENGINE TO START

RELEASEKEY

OFF

lrr

CAUTION

o not

crank the engine longer than 10 seconds at a time. If the

englnE nol

start,wait

30 seconds

to

allow the starter motor to cool and then repeat the startlng procedure. Excessive

cranking will cause damage 10

Ihe

starter.

5. Note: ff

ol pressure is

not

obtained within

30

seeonds aftar the

key is

switched

to

the RUN position,

the low-oil automatie shutdown will tum

off

tIle fuel supply. stopping the engine. Check the oil level and

tum

the

key

to the OFF pastion to reset the

oil

pressure timer before attempting to restart tIle engine.

6. Onca the engine is running, allow it to reach normal operating temperatura bafore switching any loads.

AUTOMATIC SHUTDOWN

Ths unt

s

equipped with a low oil pressure and high temperature auto-shutdown system. This systam will

automatcally shut off the fuel supply to stop the engine il ol pressure drops too low or the engine exceeds

normal operating temperatura. Return tha switch to the 'OFP position to rese Iha unit after you have

determined the cause of Ihe shutdown.

12


13/48

LlGHT OPERA

nON

1. Once theengineis

up to

temperature

and

running

smoothly,switch

main

circuitbreaker

(1) to the

on

1 position.

2.

With

maincircuitbreakeron,

switch

eachindividual

circuitbreakerforthe lights(2) loon"1", one al atime.

3. The

ballastindicator

IIghts

(3)

will

come

on

momentarilyasthelightsstrike. As thelightswarm

up

theballastindicatorlightswill continueto get

brighler

and

Ihen

remain

on.

This

confirmsthat

poweriscomingfrcmIheballeststothe

lights.

4. If an indicatorlight

does

not

come

on,

the

ballast

may

need

to

beserviced. If

the

indicatorlight

comeson and stayslitbulIherelatadlight

is

not

iIIuminatad,check

the

bulb.

5. The lightsrequireawarm upperiad of5-15 minutes

beforetheyreachfulloulput. IfIhe lights

are

shut

1 2

3

-

,

$

G =..=

-

: : : I : : ~

! 'i' ! ! ! ! 'l'

! j F-'

down,

theyrequirea

cool-clown

periodof

10

minutesbeforetheycan

be

switched

on

again.

6. The

lighttowerusesfour

1000W bu

lbs.

When

checkingorreplacingthe

bulbs, wipe

them

with

aclean

clolhtoavoid leavinganygrease,

011

residue orfingerprints

on

theglass. Any residue cancreateaho!

spot

on

the bulb,

causingpremature

bu lb

failure.

WARNING!

NEVEROPERATETHEUGHT5WITHOUT

THE

PROTECTlVELEN5

COVER ORWITH ALEN5COVERTHAT 15 CRACKEDOR DAMAGED!

ThebulbsIn

the

IIghtfixturesproduce high temperaturesand oparate

under pressure.Abroken or missing lens covereould cause

the

bulbs

to

shatter,causinginjury.

WARNING!

Bulbs becomeextremelyhot

in

use! Allow bu

lb fixture

to eool 10-15

minutesbeforehandling.

AUXILIARYOUTLETS

Thecontrol

panel

isequippedwith twooutletsforrunning

accessoriesortools from thegenerator. Powerissupplied

toIheouUets any timethe enginelsrunnlngand themain

circuitbreakerisswitchedon

"1", Note:

o

not pu/l more

than 1 W{roro each outlet when the lights are on This

willoverload

he

generatorand

cause

the

majn

circuit

breakertotrip. Should

the

breakerlrip,switchoff thelights,

remove someofthe

load lO

theoutletsand

wait 10

minutes

for

the

bubs

to cool before

tumingthem back

on.

Withallof Ihelightsoff, lhefullgeneratoroutput maybe

usedwiththeoptional

240V

twist-Iockoutlel.

120V GFCI

OUTlET

(STANDARDk

' ~ ,

240VTWIST-LOCK

OUTlET,.

(OPTIONAl) ~ .

"

13


14/48

DERATING

FOR ALTITUDE

Al! generalor

seIS

are subjecl to derating

tor

altitude and temperature. Although derating should not affect

lhe

operation of the lights, it will reduce the available power lor operating to lools

and

accessories co

necled to the auxilliary outlels. Typical reductions in performance are 2-4% tor every 1000 ft. (305 meters)

of elevation and 1%

per

l F (3-5

0

Cl

increase in ambient air temperature over 72 F (22.2

0

e).

SHUTTING

DOWN

When you have linished using the light

lower

proceed with shul down as follows:

1. Remove any loads from lhe auxillary oullels.

2. Switch lhe individual circuit breakers

tor

each light

lo the

off "O" pesilion.

3. Switch the main circuit breaker lo the off 0" position.

4. Turn the ENGINE START SWITCH lo

Ihe

OFF" position.

LOWERING

THE TOWER

1.

Shut down the lights and engine. Allow lhe lights to

cooll0-15

minutes belore lowering the lower.

2.

Tum

Ihe

masl winch

lo

collapse Ihe

lower lo

it's lowest pesition. Make sure Ihe colled electrical cord

returns to the storage tuba properly.

WARNING!

If the mast hangs up or the winch cable begins to develop slack, STOP

IMMEOIATELYI Excess slack

in the

cable could cause the rnast te

collapse should it free up wlthout warning. Contact an authorized

service center.

3. Rotate Ihe mast so the lights are lacing Ihe rear

of

the trailer and

lhe

mast winch is lacing the trailer

tongue. Tighten the knob

lor

rotating the mast lirmly.

4. Release the mas! lock by pulling Ihe salety pin

on

the mas! lock and pulling the lock free. Turn the

handle

1

the internal winch until lhe

mast

spring begins to pivot lhe tower down. Release the mast lock

and continue

lo

lower lhe tower until il resls in the cradle.

5. After lhe mast is completely down, insert lhe cradle lock pin and secure it with the salety pino

6. Pesilion IighlS

lo

aim al the ground. It the trailer is going to

be

moved, Magnum strongly recommends

thal lhe lights

be

removed trom the

mast

and stowed lor transportalion. On units equipped wilh quick

disconnect tittings

lor

the lights, disconnecllhe power cords from lhe junction

box

al lhe top

1

the mas!.

Replace the dust caps

on lhe

junclion box.

On

other units. remove the junction

box

cover

on

the lop

of the

masl

and disconnect the wires trom Ihe terminal block.

7. Remove

lhe

lighls by removing the nut Ihal holds Ihe light fixture yoke lo lhe cross tube.

14


15/48

TOWING THE TR ILER

Once the engine

is

shut down

and

the mast and lights are properly stowed, the trailer can

be

made ready

for transporto

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.

3. Use the drawbar 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. Release the jack locking pin and rotate

the jack into the travel position. Make sure the locking pin snaps into place.

4.

Connect any trailer wiring to the tow vehicle. Check for proper operation of the stop and signal lights.

5.

Make sure the cradle locking pin is

in

place.

6. Make sure the doors are properly latched.

7. If the trailer is going to

be

driven over rough ground, remove the bulbs from the light fixtures.

8.

Check for proper inflation of the trailer tires.

9. Attach a red flag

to

the end of the mast befo e towing.

10. Maximum recommended speed for highway towing is 45 mph. Recommended off-road towing speed is

not to exceed 10 mph

or

less depending on terrain.

Additional towing information

can

be found on page

6.

LlFTING THE TR ILER

When lifting the light tower and trailer, attach

ny

slings, chains or hooks directly to the centrall ifting eye.

The lifting eye is located on the mast between the two light storage brackets.

1.

Make sure the equipment being used to lift the light tower has sufficient capacity. Note:

The

Iight tower

weighs approximate/y 1850 lbs 839

kg

with

a

full tank of fue o

2.

Make sure the cradle locking pin is

in

place.

3.

Always remain aware

of

the position of other people and objects around you as you move the unit.

4.

Use the upper or lower forklift pockets with care. Approach the unit as perpendicular possible to avoid

ny damage to the unit. Make sure the mast winch handle or any other obstructions - clear

of

the

forklift tines before lifting.

CENTRAL

FORKLlFT

LlFTING E Y E ~

POCKETS

\

f ~ ~ ~ ~ ~ ~ ~ ~ ~ FORKLIFT

POCKETS

D

15


16/48

TROUBLESHOOTING THE LlGHTS

WARNINGI

HIGH VOL T AGE! 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 L1GHTS OFF BUT BALLAST INDICATORS ON CONTROL PANEL ARE ON:

1. Mast light is too ho!. Allow light to cool 10-15 minutes before restarting.

2. Faulty bulb connection. Check lhat lhe bulb is tight in the socket.

3. Bulb broken. Check

for

broken are tube or ouler bulb jacket, broken or loose components in

bulb envelope or blackeninlVdeposits inside tube.

4. Check Ihe connections inside Ihe masl junction box and eaeh mast light housinlVsocket.

5.

Check lhe mast

coi!

eord for damage and proper connection inside Ihe control box.

MAST L1GHTS OFF

AND

BALLAST INDICATORS ON CONTROL PANEL ARE OFF:

1.

Check lhe conneclions nside the control

box

and nside each ballast box.

2. Generator output incorreol. Check Ihe incoming voltage to lhe bailas!. Inooming voltage should

be 120V

/-

5V. If voltage

Is

incorrect angine speed

may

naed to be adjusted or generalor may

require servioe.

3.

Low

transformer output. The voltage from the transformer should measure 400 to

5 Vrms.

4. Low

or no ballast outpul. With the lixture cord removed Irom lhe mast junction box, the voltage

at Ihe mast eoil cord eonnection should measure 400 lo 445 Vrms. If proper voltage is not

achieved, perform capacitor check to determine if lhe capacitor

or

coil needs to be replaced.

MAST L1GHTS

ON BUT

THE L1GHT OUTPUT

18

LOW:

1.

Fixture or lens dirty. Clean reflective surface inside fixlure

and

bolh inside and outside surfaee

01

glass lens.

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

3. Check lhe masl coil cord. masl junetion box and mast light conneetions.

4. Generalor outpUI incorreet. Check Ihe incoming voltage lo lhe ballast. Incoming voltage should

be 120V

/

5V. II voltage is incorreet engine speed

may

need to be adjusted or generalor may

require service.

5.

Low

ballast output. Check ballasl for proper voltage output.

Consult pages 42-43 and page

7

for eleclrical schematics.

16


17/48

D ILY INSPE TION

1. Inspect condition 1 electrical cords. Do not use light tower il insulation

is

cut or wom through.

2. Check that winch cables are

in

good condition.

Do not

use a cable that is kinked or starting to unravel.

3. Check that the safety pins

lor

the mast and telescoping locking pins are present and secured with a

chain.

4.

Check that the springs located

in

the mast and telescoping locking pins

are

not broken

or

missing.

ENGINE

M INTEN NCE

The periodic Maintenance Schedule below lists basic maintenance intervals lor the engine. For detailed

maintenance procedures refer to the Engine Operator s Manual. A copy of this manual was supplied with

the unit when it was shipped from the factory. For additional

or

replacement copies 01 the Engine

Operator's Manual contact an authorized engine dealer in

your

area.

Every Every Every

Every

Every Every

Every

50 100 200 400 500 800

Two

hours hours

hours hours hours hours

years

Check lor fuel leaks.

Change engine oil.

Clean air cleaner element.

Clean fuel filler.

Check level of battery electrolyte.

Check condition and tension on fan bel .

Replace oil

filter

Check condilion

of

radiator hoses.

Replace fuel filter.

Remove sediment in fuel tank.

Flush radiator.

Replace fan bel .

Check all electrical connections.

Change radiator coclan .

Check valve clearance.

Replace radiator hoses and clamps.

Replace fuel pipes and clamps.

Replace air aleanar element.

Once

ayear or

every six cleanings.

Changa engine oil and filler afiar first

5

hours

of

oparation.

17


18/48

OECAL LOCATIONS

ONENGINE

F NGU RD

INSIDE

DOOR

INSIDE

DOO

18


19/48

DECAL LOCATIONS

t

ON GENER TOR INSI E

HOUSING OOR

19


20/48

oeC L LOC TIONS

ABOVE RADIATOR (CAT ENGINE)

BELOW RADIATOR

M I T S U , ~ E ~ N : : : G : : : I N : E : ~ ~ - t i l

www.m p lIc.com

INSIDE ANO OUTSIDE

ABOVE

EXHAUST

PIPE

ABOVE

RADIATOR

CAP

UNITSETUP

INSTRUCTION

OECAL

NEXT

TO

GROUND

STUD


21/48

DECALLOCATlONS

ON MANUAL

HOLDER

ON TOP OF BALLAST

ONTOPOF

OXES BOTH

SIDES

_ ~ ~ ~ ~ O N T R O

BOX

ONTOPOF

CONTROLBOX

21


22/48

M NU LWI

H M STASSEMBLY

11


23/48

1

2

3

4

5

6

7

8

9

10

12

13

14

15

16

17

18

19

20

2

22

23

24

25

MANUAL WINCH MAST ASSEMBLV

ITEM NO PARTNO

10008

14448

15006

15380

14261

15015

15014

15002

15003

14151

15013

150088

162578

111368

15829

14439

111428

111138

14526

60247

15292

14734

150018

14234

14278

QTY

1

1

1

4

2

3

4

2

1

1

4

1

1

1

1

1

1

1

1

1

1

2

1

1

1

DESCRIPTION

Guard, coil cord

Winch, manual

Cable, mast 27'

Pin, cottar

Pulley,2"

Pin, clavis 1/2 x 1 1/4

Shim, plastic 2"

x

3"

Clamp, cable

Thimbla, cable

Cable, uppar mast 11'

Shim, plastic 2"

x

2"

Section, mast 3"

Section, mast 2"

8racket, junction box

Reflector, mast

Grip, cord

Crossarm, 4-light

Section, mast 4"

Knob, locking

Washer, tlat

80lt, 3/4-10

x

61/2

Nut, nylock 3/4-10

Tube, mast

Pin, clevis

Cord, coil7-conductor (not shown)

23


24/48

FR ME

NO

COMPONENTS

e

3 ~ ~

3 ~

4

14

4 ~

41

42


25/48

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

FRAME ANO COMPONENTS

ITEM

NO PARTNO

110658

16088

11054

110578

148458

14261

14234

14222

14326

11082Z

14448

14324

15543B

14521

16830

16741

16835

16999

11100

15976

60096

60504

19637

60503

110946

142576

14223

111466

14146

110518

15380

14275

14663Z

14403

15165

15153

11206

11201

11207

16679

11202

11203

14798

10252

10253

10254

QTY

2

1

1

1

1

1

1

3

4

2

1

2

1

2

1

1

1

1

1

2

10

6

4

6

2

1

2

1

2

1

1

1

1

1

1

1

2

4

10

2

2

8

1

1

1

1

5

OESCRIPTION

Strap, fuel tank

Cap, fuel tank 3.5"

Tank, fuel wf3.5

fill

neck

Weldment, mast post

Kickback spring, mast

Pulley,2"

Pin, clevis 2"

Jack, top wind complete

Ring, retaining

Weldment, outrigger

Winch, manual

Kit, plunger

Weldment, tongue

Chain, safety

Hitch, ball 2"

Hitch, combo (oplional)

Hitch, Lunette ring 3" (optional)

Hitch, Lunette ring 2 1/2 (oplional)

Axle, 2200

lb.

Wheel,13"

Lug nut, axle

Nul, 9/16 - 18

Plate, shackle bracket

Screw, 9 16 18

Bracket, control box

Weldment, control box

Jack, side wind complete

Holder, battery

J-bolt, battery

Weldment, trame

Pin, cotter

Spring, lock

Bar,latch

Pin, cotterless

Pin, roll

8attery, startng

Hub, axle (with wheel studs)

U-boll, axle

Wheel stud, axle

Spring, axle

Tie plate, spring

Nul, 1/2-20 locking

Cable. winch 16' (nol shown)

Kit, handle top wind jack (nol shown)

Kit, handle side wind jack (not shown)

Kil, jack bevel gears(not shown)


26/48

9

4

3

METALENCLOSURECOMPONENTS

1 ~

3 1

~

1

19

2 _ ~

1

5

~

16

18

26


27/48

METAL ENCLOSURE COMPONENTS

ITEM NO.

1

2

3

4

5

6

7

8

9

1

11

12

13

14

15

16

17

18

19

2

21

PART NO.

16560

11061W

11066W

11095

11091Z

15018Z

14797

11096W

11062W

15123

11060W

10224

10220

10219

65406

11097W

11098W

11077W

65407

14459B

14651

QTY

2

1

2

2

1

1

1

1

1

2

1

1

1

2

2

1

1

1

2

1

2

DESCRIPTION

Fender, plastic

Panel, side (L)

Panel, door

Hinge, door

Cradle, mast

Pin, cradle

Bumper, cradle

Panel, radiator cover

Panel, top

Latch, paddle

Panel, rear (Mitsubishi engine)

Bracket, license plate

Light, license plate

Light, tum signal

Light, maker red

Panel, rear (Cat engine)

Panel, side (R)

Panel, front

Light, marker anber

Bracket, door adjusting

Latch, door (not shown)

27


28/48

CATERPILLAR

ENGINE

NDGEN

ERATOR

3

A

I

i ~

19

8

5

2

t

(

~ ~ ~ ~ ~ ~ ; :

"

~ ~ i / '

' ~ ~ : ~ , : : : : : : : ; / 4

U \ ~ . > - ~ 1 2

0

11


29/48

1

2

3

4

5

6

7

8

9

10

12

13

14

15

16

17

18

19

20

2

22

23

24

25

26

27

28

29

30

3

32

33

CATERPILLAR ENGINE AND GENERATOR

ITEM NO

PARTNO

11165

11152B

16778

Page

4

11153B

11154

11155

11156

11157

11158

15241

15045

60014

14410

60047

60044

14216

19220

11159

11160

16782

22419B

16683

11161

11162

11163

11164

15074

15073

15695

15493

15492

11129

TV

1

2

1

1

1

1

1

1

1

1

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

3

1

1

1

1

1

DESCRIPTION

Radiator, Calerpillar

Bracket, engine

Engine, Caterpillar

Generalor, 6 kW

Brackel, air cleaner

Clamp, air cleaner

Hose, radiator upper

Hose radiator lower

Hose, air cleaner

Housing, air cleaner

Mount, compression

Mount, generalor

Screw, M6 x 35

Bottle, overflow (w/clamp)

Nul, nylock M6

Screw, M5 x

2

Clamp, hose

Hose, overflow

Guard, fan (L)

Guard, fan (R)

Muffler, engine

Bracket, overflow bottle

Solenoid, fuel (not shown)

Kit, fuel filler (nol shown)

Element, air cleaner (nol shown)

Filler, oil (nol shown)

Glow plug, engine (nol shown)

Cable, battery red 38 (nol shown)

Cable battery black 25 (nol shown)

Capacitor, generalor (nol shown)

Diode, generalor (not shown)

Suppressor (nol shown)

Shroud, radiator (not shown)

29


30/48

ENGINE

NO GENER TOR COMPONENTS

2 ~ :

5 2 ~

t

~ ~ f J >

______ 13

f J > ~

2

ITEMNO

1

2

3

4

5

6

7

8

9

10

2

13

4

15

4

PARTNO

16540

16554B

16553B

16597

Page 4

16551B

16552B

16687

16588

16589

16443

524

15 45B

16535B

1441

1

3

/

25

QTY

1

1

1

1

1

1

1

1

1

1

1

4

1

2

1

16

I

17

~ ~ 5

~ 8

3

19

DESCRIPTION

Radiator, Mitsubishi

Mount, engine L)

Mount, engine R)

Engine, Mitsubishi

Generator, 6

kW

Bracket, air cleaner

Bracket, fuel filter

Hose, radiator upper

Hose radiator lower

Hose, air cleaner

Housing, air cleaner

Mount, compression

Mount, generator

Bracket, radiator

Bottle, overflow

CONTINUED ON NEXT P GE

3


31/48

ENGINE NO GENER TOR COMPONENTS

ITEMNO

PARTNO

QTV

DESCRIPTION

16 16724

1 Guard, fan

17

19257 1 Fitting, oil drain

18 60501

1 Elbow, 45 deg.

19 19167

1 Hose, oil drain

20 19301

Cap, oH drain

21 16742

1 Fan, engine

22 19219

1 Cap, radiator

23

22419B

1 Bracket, overflow bottle

24 16832 1 Head, fuel filter

25

16686 1 Element, fuel fil ler

26

15266

1 Muffler, engina (nol shown)

27 16677

1

Switch, oil pressure (not shown)

28

16678 1

Switch, temperatura (not shown)

29 16683

1 Solenoid, fuel nol shown)

30

16684 1 Kit, fuel feed (not shown)

31 16689 1 Support, hosa (nol shown)

32 16444

1 Element, air cleaner (not shown)

33 16445

Brackel, air cleaner clamp (not shown)

34 16691

Filler, o (nol shown)

35

16692

1 Belt, altamalor (nol shown)

36 16693

3 Glow plug, engine (nol shown)

37 15074

1 Cable, battery red 38" (nol shown)

38 15073 1 Cable battery black 25" (nol shown)

39 15695 1

Capacilor, generalor (not shown)

40

15493 1 Diode, generator (nol shown)

41

15492

Suppressor (nol shown)

42

15212

Generator, 8 kW (nol shown, oplional)

43

11148 1

Dip stick, engine

oi

(nol shown)

44 11147

Cap, oi filler (not shown)

5

16134

1

Bearing. generalor (nol shown)

46

16833 1 Starter, angine Mitsubishi (nol shown)

47

48

49

16743

16744

16745

1

1

1

Altemator, Mitsubishi (nol shown)

Water pump, Mitsubsh (nol shown)

Thermoslat, Milsubish nol shown)

50 11226

Push rod, engine Milsubishi (nol shown)

51

11228 Lifter, engine Milsubishi (nol shown)

52 11262

Injector, fuel w seals (nol shown)

53 11209 1

Gaskel, valve cover (nol shown)

54

11227 1

Kil, engine gaskel (nol shown)

55 16874

1 Hamess, engine eleclrieal (nol shown)

56

11208

Manual, workshop Mitsubishi

57

16730

Manual, engina parts Milsubishi

58

16729

Manual, angine operation Milsubishi

31


32/48

CONTROL

PANEL

ASSEMBLY

CATERPILLAR ENGINE

ITEMNO

1

2

3

4

5

6

7

8

10

12

13

,

,

C

J

Cj

PARTNO TY

14248

1

14249 4

65325 4

65388 1

11176

1

11177 1

15085 1

14156

1

14130 1

14137 1

10081

1

16237 1

65415

1

3

12

DESCRIPTION

Breaker, main 30A

Switch, toggle 15A

Light, indicator ballast)

Light, indicator main breaker)

Switch, engine

Indicator, glow plug

Gauge, hourmeter

Breaker, 20A

Outlet, 120V GFIC

Outlet, 240V twist lock optional)

Hinge, panel

Panel, control Cal engine)

Breaker, 40A w/8 kW option)


33/48

CONTROL PANEL ASSEMBLV

MITSUBISHI ENGINE

10

< ~ ~

< l

9

1

O" ~

.

. \;)

:CJ.

7

,

5

12

ITEM NO. PARTNO.

1 14248

2

14249

3

65325

4

65388

5

15195

6 16694

7

15085

8 14156

9

14130

10

14137

11

10081

12

10235

13

65415

14 16734

QTV

1

4

4

1

1

1

1

1

1

1

1

1

1

1

DESCRIPTION

Breaker, main 30A

Switch, t09gle 15A

Light, ndicator (ballast)

Light, indicator (man breaker)

Switch, engine

Indicator, glow plug

Gauge, hourmeter

Breaker, 20A

Outlet, 120V GFIC

Outlet, 240V twist lock (optional)

Hinge, panel

Panel, control (Mitsubishi angine)

Breaker,40A (w/8 kW option)

Panel, control (w/8 k generator option)

33


34/48

CONTROL BOX ASSEMBLV

7

ITEM NO.

1

3

4

5

6

7

8

9

8

~

I ~

/ {

,

:

,

,

I

PARTNO.

14202

10241

11121

14257B

14201

14841

14203

14204

14219

9

QTV

5

1

1

1

1

1

1

DESCRIPTION

Connector, 3/8 Romex

Clamp, manual holder

Holder, manual

Weldment, control box

Relay, auto shutdown

Breaker, 10A

Strip, terminal

Bar, ground

Connector, 3/4 Romex

34


35/48

HIGH PRESSURE SODIUM

LlGHT

ASSEMBLV

13

3

8

9

WARNING!

DO NOT MIX HIGH PRESSURE

SOOIM

ANO

METAL HAUDE

BULBS

R PARTSI

ITEM

NO.

PARTNO. QTV

DESCRIPTlON

1 15864

1

Connector, cord

2

597 1

Housng, alumnum

3

14632

1

Yoke, light

4 14166 1

Cord, quck dsconnect (optonal)

5

14634 1

Cord, hard wred light

6

1473

1

Socket, light

7

16758

1 Reflector, aluminum

8

16499 1

Gasket, hood

9

16272 1

Ring, renforcement

1

14784

1

Bulb, hgh pressure sodum

676

1

Support, bu lb

2

16718

1

Ring, clamp

13 1675

1 Lens,lght

14 16757

1

Assembly, cable

15 16759 Fixture, complete (quick disconnect)

16

1676

Fixture, complete (hard wired cord)

35


36/48

METAL HALIDE LlGHT ASSEMBLV

WARNINGI

DO

NOT MIX HIGH

PRESSURE

SODIM ANO METAL HALlDE

BULaS OR

PARTSI

ITEMNO

1

2

3

4

5

6

7

8

9

1

11

12

13

14

15

16

PARTNO

15864

15971

14632

14166

14634

1473

16758

16499

16272

14217

16761

16718

1675

16757

16746

16747

QTV

1

1

1

1

1

1

1

1

1

1

1

1

1

1

36

DESCRIPTION

Connector. cord

Housing. aluminum

Yoke, light

Cord, quick disconnect optional)

Cord. hard wired light

Socket, light

Reflector, aluminum

Gasket, hood

Ring, reinforcement

Bulb, metal halide

Support, bulb

Ring, clamp

Lens,light

Assembly, cable

Fixture, complete including plug)

Fixture, complete


37/48

QUICK DISCONNECT MAST JUNCTION BOX ASSEMBLV

-

4

7

ITEM NO.

1

2

3

4

5

6

7

PARTNO

14278

15863

15697

16394

15403

15404

15402

QTV

1

5

1

4

4

5

DESCRIPTlON

Cord, coil 7-conductor

Strain relief, cord

Washer, rubber seal

Junctlon box, mast

Plug, quick disconnect female)

Cap, receptacle w/chain

Cover, junction box

37


38/48

M ST JUNCTlON

BOX

SSEMBLY

ITEM NO

1

2

3

4

5

6

7

-

2 - - - _ - d i

3

PARTNO

QTY

14278 1

15863

1

15697

5

15861

4

16081 1

15217

15864

4

8

DESCRIPTlON

Cord coil7-conductor

Strain relief cord

Washer rubber seal

Nut lock

Junction box mast

Strip terminal

Strain relief. cord


39/48


40/48


41/48


42/48


43/48


44/48


45/48


46/48


47/48


48/48

manual - planta magnun

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