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Magnum MLT 5150 Operating & Parts Manual

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LIGHT TOWER
MLT 5150 • 5200
www.discount-equipment.com
OPERATING/PARTS MANUAL

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Summary of Contents for Magnum MLT 5150

  • Page 1 LIGHT TOWER MLT 5150 • 5200 www.discount-equipment.com OPERATING/PARTS MANUAL...
  • Page 2 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mayco, Toro/Stone, Diamond Products, Magnum, Airman, Mustang, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand Brothers, Essick, Miller Spreader, Skyjack, Lull, Skytrak,...

  • Page 3: Introduction

    The information contained in this manual was based on machines in production at the time of publication. Magnum Products LLC reserves the right to change any portion of this information without notice.

  • Page 4: Table Of Contents

    FRAME ASSEMBLY ......................36 - 37 COOLING SYSTEM ASSEMBLY ................... 38 - 39 ENGINE ASSEMBLY - MLT 5150, MITSUBISHI ..............40 - 41 ENGINE ASSEMBLY - MLT 5200, ISUZU ................42 - 43 CONTROL BOX AND PANEL ASSEMBLY ................44 - 45 LIGHT ASSEMBLY .........................

  • Page 5: Safety Notes

    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.

  • Page 6: Engine Safety

    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. Also read and follow all safety warnings described in the engine operator’s manual. A copy of this manual was supplied with unit when it was shipped from the factory.

  • Page 7: Towing Safety

    If you believe your trailer has a defect which could cause a crash or could cause injury or death, you should immedi- ately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Magnum 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.

  • Page 8: Safety Symbol Summary

    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 beginning of the parts section of this manual.

  • Page 9: Specifications

    Read all of the manuals included with this unit. Each manual details specific information regarding items such as set up, use and service requirements. Specifications are subject to change without notice. MAGNUM MODEL MLT 5150 MLT 5200 Engine Make/Brand ............Mitsubishi ........Isuzu Model ..............
  • Page 10 Read all of the manuals included with this unit. Each manual details specific information regarding items such as set up, use and service requirements. Specifications are subject to change without notice. MAGNUM MODEL MLT 5150/5200 Lighting Lighting Type ............Metal Halide Ballast Type ............Coil & Core Lumens ...............

  • Page 11: Light Tower Set Up

    LIGHT TOWER SET UP 1. For maximum light coverage locate tower at ground level or in a spot higher than the area being illuminated by the lamps. WARNING The tower extends up to 30 ft (9.14 m). Make sure area above the trailer is open and clear of overhead wires and obstructions.

  • Page 12: Raising The Tower

    RAISING THE TOWER WARNING The trailer must be leveled with the outriggers extended before raising the tower. The outriggers must remain extended while the tower is up. Failure to level the trailer or extend the outriggers will severely reduce the stability of the unit and could allow the tower to tip and fall. 1.

  • Page 13: Raising The Tower With Optional Electric Winch

    RAISING THE TOWER WITH THE OPTIONAL ELECTRIC WINCH 1. Set up and level the trailer as described on page 10, and follow steps 1-3 on page 11. 2. Remove the safety pin from the mast lock bar (R). 3. Press the lower winch control toggle switch upward to raise mast into the vertical position (S).

  • Page 14: Main Control Panel Components

    MAIN CONTROL PANEL COMPONENTS PRODUCTS LLC BERLIN, WI. USA 1-800-926-9768 1. MAIN CIRCUIT BREAKER (70A or 100A): This breaker will disconnect power to the lights and auxiliary outlets. 2. BALLAST INDICATOR LIGHTS: Indicates power from the ballast to each light. 3.

  • Page 15: Engine Starting And Operation

    ENGINE STARTING AND OPERATION 1. Check engine oil, fuel and coolant levels. 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 operators manual supplied with the unit. 2.

  • Page 16: Light Operation

    LIGHT OPERATION 1. Once the engine is up to temperature and running smoothly, switch main circuit breaker (1) to the ON “I” position. 2. With main circuit breaker on, switch each individual circuit breaker for the lights (2) to ON “I”, one at a time. 3.

  • Page 17: Voltage Regulation

    5. After the mast is completely down, insert the cradle lock pin and secure it with the safety pin. 6. Position lights to aim at the ground. If the trailer is going to be moved, Magnum Products LLC strongly recom- mends that the lights be removed from the mast and stowed for transportation.

  • Page 18: Lowering The Tower With The Optional Electric Winch

    5. After the mast is completely down, insert the cradle lock pin and secure it with the safety pin. 6. Position lights to aim at the ground. If the trailer is going to be moved, Magnum Products LLC strongly recom- mends that the lights be removed from the mast and stowed for transportation.

  • Page 19: Lifting The Trailer

    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 engine speed may need to be adjusted or generator may require service. Contact Magnum Products Technical Service Depart- ment for more information.

  • Page 20: Mast Light Connections

    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 discon- nect 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 lights and ground.

  • Page 21: Daily Inspection

    DAILY INSPECTION 1. Inspect condition of electrical cords. DO NOT use light tower if insulation is cut or worn through. 2. Check that winch cables are in good condition and that they are centered on each pulley. DO NOT use a cable that is kinked or starting to unravel.

  • Page 22: Engine Maintenance

    ENGINE MAINTENANCE Note: During the first 50 hours of operation, avoid long periods of no load or sustained maximum load operation. If the light tower is to run for longer than five minutes without a load, shut the engine down. The engine is supplied with engine break-in oil from the factory.

  • Page 23: Unit Decals

    LE MÂT EN BAS ET PROTÉGÉ DANS LE BERCEAU! Electric Winches ITEM NO. PART NO. DESCRIPTION 12141 Decal set, LT eng/safety 4-lang 11275 Decal, Magnum logo w/ web - red vinyl 12262 Decal, 4000/5000 set up 4-lang (MW) 12880 Decal, instruction 4000/5000 4-lang (EW)
  • Page 24 ITEM NO. PART NO. DESCRIPTION 12140 Decal set, common mast 4-lang 12141 Decal set, LT eng/safety 4-lang 16488 Decal, Magnum logo w/ red stripe 12142 Decal, ground 10420 Decal set, MLT4150-4200, MLT5150-5200 22960 Decal, breaker 20 amp 23203 Decal, breaker 30 amp...
  • Page 25 ADVERTISSEMENT WARNUNG DANGER WARNING ADVERTENCIA ADVERTISSEMENT GEFAHR PELIGRO DANGER WARNUNG ADVERTENCIA ADVERTISSEMENT WARNING WARNUNG ADVERTENCIA ADVERTISSEMENT ITEM NO. PART NO. DESCRIPTION 12140 Decal set, common mast 4-lang 12141 Decal set, LT eng/safety 4-lang 16488 Decal, Magnum logo w/ red stripe...
  • Page 26 UNIT DECALS DANGER DO NOT REMOVE! GEFAHR ENTFERNEN SIE NICHT! PELIGRO NO QUITE! DANGER N'ENLEVEZ PAS ! This decal is also located on the bottom side of mast Located on inside of mast junction box. ITEM NO. PART NO. DESCRIPTION 12140 Decal set, common mast 4-lang 12141...

  • Page 27: Manual Winch Mast Assembly

    MANUAL WINCH MAST ASSEMBLY...
  • Page 28 ITEM NO. PART NO. DESCRIPTION 15612 Cable, 16-7 cold mast drape (optional) 11954 Coil cord, mast 16600 Winch, manual 15623 Winch handle, 9” long with nut 16143 Clamp, tubing .500 15006 Cable, .188 in. x 27 ft. w/ball swedge 15380 Pin, cotter - .125 x 1.250 14262 Sheave, 3 in.

  • Page 29: Electric Winch Mast Assembly

    ELECTRIC WINCH MAST ASSEMBLY...
  • Page 30 ITEM NO. PART NO. DESCRIPTION 15612 Cable, 16-7 cold mast drape (optional) 11954 Coil cord, mast 12872B Bracket, winch mounting 65707 Switch, toggle - SPDT spring weatherproof 65049 Relay, 12V 30/40A N.O. w/diode 11293 Contactor, electric winch - warn 12875B Cover, winch contactor 12292 Boot, battery cable red...

  • Page 31: Auxiliary Outlet Panel Assembly

    AUXILIARY OUTLET PANEL ASSEMBLY...
  • Page 32 ITEM NO. PART NO. DESCRIPTION 65535 Clamp, 90° 3/4" 2 screw 12248B Weldment, outlet cover 10081 Hinge, continuous - 11.00 in. 11484B Cover, breaker 14130 Receptacle, 120V 20A GFCI 65530 Block, terminal - 2 pole lug type, 7 pos./pole 14137 Receptacle, 240V 30A twist lock 18089 Receptacle,120/ 240V 50A twist lock...

  • Page 33: Auxiliary Outlet Panel Options

    AUXILIARY OUTLET PANEL OPTIONS PART NUMBER 12399 PART NUMBER 12402 Receptacle Panel (2x5-20R, 3xL6-30R, 1x50A) Receptacle Panel (2x5-20R, 3xL6-20R, 1x50A) PART NUMBER 12400 PART NUMBER 12401 Receptacle Panel (2x5-20R, 3xL14-30R, 1x50A) Receptacle Panel (2x5-20R, 4xL14-30R)
  • Page 34 PART NUMBER 13540 Receptacle Panel (2x5-20R, 1xTT-30R, 1xL6-30R, 2x50A) ITEM NO. PART NO. DESCRIPTION 14130 Receptacle, 120V 20A GFCI 14137 Receptacle, 240V 30A twist lock 18089 Receptacle, 125/250V 50A twist lock 65488 Receptacle, 240V 30A twist lock 65849 Breaker, 20A, 120V, 1 pole, push button 65851 Breaker, 30A 250V 2 pole (JA) screw term, w/aux 65492...

  • Page 35: Enclosure Assembly

    ENCLOSURE ASSEMBLY...
  • Page 36 ITEM NO. PART NO. DESCRIPTION 25333W Panel, back access 12195 Gasket, radiator access plate 11935 Pad, rubber 2.00 x 2.00 x 1.00 16099 Assembly, cradle pin 12119W Panel, top - MLT5000 12253B Weldment, light storage, upper rear 12252B Weldment, light storage, upper middle 12605 Door latch SS - T-style 12251B...

  • Page 37: Frame Assembly

    FRAME ASSEMBLY 4, 61...
  • Page 38 ITEM NO. PART NO. DESCRIPTION 15142 Fitting, .250NPT x .312 hose barb 16271 Fitting, .250NPT x .188 hose barb 16270 Fitting, .375NPT x .250FNPT 12137 Cap, fuel tank vent 3.5 dia. green w/lanyard 12120B Panel, fuel tank support 11057B Weldment, mast post 11554Z Spacer plate, kickback spring 14845B...

  • Page 39: Cooling System Assembly

    COOLING SYSTEM ASSEMBLY LOWER RADIATOR HOSE...
  • Page 40 Washer, #10 flat .435/.060 SS 60696 Washer, .250 flat .625/.050 SS USS 14410 Assembly, overflow jug (1.5 qt) (items 11-20) OPTIONAL FEATURES: 65650 Heater, engine - low rad hose (MLT 5200) 65648 Heater, engine - low rad hose (MLT 5150)

  • Page 41: Engine Assembly - Mlt5150, Mitsubishi

    ENGINE ASSEMBLY - MLT5150, Mitsubishi...
  • Page 42 ITEM NO. PART NO. DESCRIPTION 19270 Element, air filter 16443 Assembly, air filter with bracket 16445 Bracket, air cleaner housing 60018 Screw, M10X1.25X20 hx ser flg 60316 Clamp, hose - SAE 032 (1.56-2.50) 12314 Hose, air cleaner 16684 Kit, fuel feed with fittings 11745B Bracket, fuel/air filter 11821B...

  • Page 43: Engine Assembly - Mlt 5200, Isuzu

    ENGINE ASSEMBLY - MLT 5200, Isuzu...
  • Page 44 ITEM NO. PART NO. DESCRIPTION 12969 Filter, air - metallic 61091 Screw, .312-18X1.000 ser flg hx G5 12990B Bracket, air filter 60018 Screw, M10-1.25X20 ser flg hx G10.9 60316 Clamp, hose - SAE 32 60095 Nut, .312-18 ser flg G5 case hard 22320 Hose, air filter 12421B...

  • Page 45: Control Box And Panel Assembly

    CONTROL BOX AND PANEL ASSEMBLY...
  • Page 46 Panel, control (MLT 5200) 11887 Panel, control (MLT 5150) 65429 Breaker, 100A 250V 2 pole (MLT 5200) 60736 Breaker, 70A, 250V, 2 pole (MLT 5150) 65388 Light, indicator red - w/wire 12 VDC 65325 Light, indicator green - w/wire 12 VDC 14249...

  • Page 47: Light Assembly

    LIGHT ASSEMBLY...
  • Page 48 Block, terminal - 2 pos, 90A, 600V 11424 Reflector, end Magnum light 11399 Reflector, wrap around - Magnum light 11423 Reflector, hole in end - Magnum light 12993Z Weldment, wing nut - Magnum light 60369 Washer, ext star lock M12 12991Z...

  • Page 49: Metal Halide Ballast Box Assembly

    METAL HALIDE BALLAST BOX ASSEMBLY WARNING DO NOT mix metal halide and high pressure sodium ballast parts! ITEM NO. PART NO. DESCRIPTION 11079 Cover, ballast box 14679 Capacitor, metal halide 11166 Transformer, metal halide 10227 Assembly, transformer & cap set 14158 Block, terminal 11078...

  • Page 50: High Pressure Sodium Ballast Box Assembly - Optional

    HIGH PRESSURE SODIUM BALLAST BOX ASSEMBLY WARNING DO NOT mix high pressure sodium and metal halide ballast parts! ITEM NO. PART NO. DESCRIPTION 11079 Cover, ballast box 14782 Capacitor, sodium light 14783 Ignitor, sodium light 11167 Transformer, sodium light 11168 Assembly, transformer &...

  • Page 51: Mast Junction Box Assembly - 4 Light, Quick Disconnect

    MAST JUNCTION BOX ASSEMBLY - QUICK DISCONNECT LIGHTS ITEM NO. PART NO. DESCRIPTION 12109 Box cover, 2-gang plastic 66100 Connector, 2 pos. Wago 66101 Connector, 3 pos. Wago 66102 Connector, 5 pos. Wago 60755 Fitting, .750MNPT x .500FNPT nylon 15403 Connector, quick disconnect (female) 15404 Cap, receptacle w/chain...

  • Page 52: Mast Junction Box Assembly - 6 Light Quick Disconnect

    MAST JUNCTION BOX ASSEMBLY - 6 LIGHT QUICK DISCONNECT ITEM NO. PART NO. DESCRIPTION 12109 Box cover, 2-gang plastic 66100 Connector, 2 pos. Wago 66101 Connector, 3 pos. Wago 66102 Connector, 5 pos. Wago 60755 Fitting, .750MNPT x .500FNPT nylon 15403 Connector, quick disconnect (female) 15404...

  • Page 53: Generator Assembly - Mlt 5150

    GENERATOR ASSEMBLY - MLT 5150 ITEM NO. PART NO. DESCRIPTION 12736 Cover, generator box 18556 Regulator, voltage - SE 350 11327 Generator, 15 kW, 60 Hz regulated 11597B Bracket, gen mount 11524 Compression mount, 4.38x4.00x1.50...

  • Page 54: Generator Assembly - Mlt 5200

    GENERATOR ASSEMBLY - MLT 5200 ITEM NO. PART NO. DESCRIPTION 12736 Cover, generator box 18556 Regulator, voltage - SE 350 60495 Screw, M10-1.25X16 hx hd G8.8 60026 Washer, split lock M10 11000 Plate, drive - SAE 7.5 (Isuzu 3LB1) 11515B Spacer, 2.00 dia x 1.00 12469 Compression mount, 4.38X2.00X1.50...

  • Page 55: Wiring Diagrams

    MAST JUNCTION BOX WIRING DIAGRAM...
  • Page 56 AC WIRING DIAGRAM Receptacle panel part number 12398 shown (2x5-20R, 2xL6-30R, 2x50A). CONNECTIONS TO TERMINAL BLOCK 1 CONTINUED ON FOLLOWING PAGES...
  • Page 57 AC WIRING DIAGRAM - 4 LIGHT CONNECTIONS TO TERMINAL BLOCK 1 CONTINUED FROM PAGE 55...
  • Page 58 AC WIRING DIAGRAM - 6 LIGHT CONNECTIONS TO TERMINAL BLOCK 1 CONTINUED FROM PAGE 55...
  • Page 59 AC WIRING PANEL OPTIONS PART NUMBER 12399; Receptacle Panel (2x5-20R, 3xL6-30R, 1x50A) PART NUMBER 12402; Receptacle Panel (2x5-20R, 3xL6-20R, 1x50A) PART NUMBER 12400; Receptacle Panel (2x5-20R, 3xL14-30R, 1x50A)
  • Page 60 AC WIRING PANEL OPTIONS PART NUMBER 12401; Receptacle Panel (2x5-20R, 4xL14-30R) CIRCUIT CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER BREAKER BREAKER 30 AMP 30 AMP 50 AMP 50 AMP 120 VOLT 240 VOLT 240 VOLT 240 VOLT 30 AMP 30 AMP 50 AMP 50 AMP TWIST LOCK TWIST LOCK...
  • Page 61 DC WIRING DIAGRAM - MLT 5150...
  • Page 62 DC WIRING DIAGRAM - MLT 5200...
  • Page 63 DC CIRCUIT WIRING DIAGRAM - DUAL ELECTRIC WINCH ELECTRIC WINCH (OPTIONAL) WINCH WINCH PROX. PROX. RELAY RELAY PROX SWITCH PROX SWITCH TILT EXTEND 50 AMP CIRCUIT BREAKERS BATTERY 12V...
  • Page 64 TRAILER LIGHTS WIRING DIAGRAM ITEM NO. PART NO. DESCRIPTION 10264 Harness, left side trailer 12602 Assy, trailer light harness - 5000 10265 Harness, right side trailer 65441 Adapter, pig-tail trailer light 4-pin to 12-pin 65465 Adapter, trailer wiring flat 4 to rnd 7 blade 65464 Adapter, trailer wiring flat 4 to rnd 7 pin 65463...
  • Page 65 www.discount-equipment.com REV: P PART NO: 11632 09.16.08...

This manual is also suitable for:

Mlt 5200

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