Magnum MLT5060 Operating & Parts Manual
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Magnum MLT5060 Operating & Parts Manual

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LIGHT TOWER
MLT5060 • MLT5080
OPERATING/PARTS MANUAL

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Summary of Contents for Magnum MLT5060

  • Page 1 LIGHT TOWER MLT5060 • MLT5080 OPERATING/PARTS MANUAL...

  • Page 2: Introduction

    Occupational Safety and Health Association (OSHA) guidelines. Keep a copy of this manual with the unit at all times. Additional copies are available from Magnum Products LLC. An engine operators manual was also supplied with the unit at the time of shipment from the factory. The manual provides detailed operation and maintenance procedures for the engine.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Page INTRODUCTION ..........................2 TABLE OF CONTENTS ........................3 SAFETY NOTES ..........................4 OPERATING SAFETY ........................4 ENGINE SAFETY ........................... 5 SERVICE SAFETY ......................... 5 TOWING SAFETY .......................... 6 UNIT SERIAL NUMBER LOCATIONS ....................6 SAFETY SYMBOL SUMMARY ....................... 7 SPECIFICATIONS ........................

  • Page 4: 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 5: 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 6: 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 7: 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 8: 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 5060 Engine Make/Brand ............
  • Page 9 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 5060 Lighting Lighting Type ............
  • 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 5080 Engine Make/Brand ............
  • Page 11 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 5080 Lighting Lighting Type ............

  • Page 12: 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 13: 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 14 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 15: Main Control Panel Components

    MAIN CONTROL PANEL COMPONENTS MAIN BREAKER 240V BALLAST INDICATOR LIGHTS LIGHT LIGHT LIGHT LIGHT 120V GLOW PLUG INDICATOR TURN GLOW MAIN PLUG START BREAKER 240V HOURS NEUTRAL BONDED TO FRAME CONDUCTOR NEUTRO CONECTOADO AL CHASIS 1. MAIN CIRCUIT BREAKER (30A or 40A): This breaker will disconnect power to the lights and auxiliary outlets. It will also disable the starting circuit if engine starting is attempted when the main breaker is on.

  • Page 16: 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 operation manual supplied with the unit. 2.

  • Page 17: Light Operation

    (U/F). If equipped, the voltage regulator on your unit is adjusted before shipment from the factory. Contact Magnum Products LLC for additional information before attempting to adjust the voltage regulator.

  • Page 18: Derating For Altitude

    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 recommends that the lights be removed from the mast and stowed for transportation. On units equipped with quick disconnect fittings for the lights, disconnect the power cords from the junction box at the top of the mast.

  • Page 19: Towing The Trailer

    Remove the lights by removing the wing nut that holds the light fixture INSERT bracket to the cross tube. Insert the lights into the storage brackets VERTICAL inside the unit, placing two lights into the roof mounted brackets first. LAMP FIRST Then, place a light into the vertical bracket next to the engine with the last light going into the angled bracket.

  • Page 20: Lifting The Trailer

    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. Release the jack locking pin and rotate the jack into the travel position.

  • Page 21: Trailer Wheel Bearings

    PROPER MAST CABLE ROUTING 3. 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. 4.

  • 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: Optional Lower Radiator Hose Heater Use And Maintenance

    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 Department for more information.

  • Page 24: Mast Light Connections

    MAST LIGHT CONNECTIONS MAST JUNCTION BOX WIRING MAST LIGHT CONNECTIONS 4-LIGHT 4-LIGHT MAST LIGHT CONNECTIONS MAST JUNCTION BOX WIRING 6-LIGHT 6-LIGHT...

  • Page 25: Unit Decals

    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) 12881 Decal, instruction 3000 4-lang (EW) 12880 Decal, instruction 4000/5000 4-lang (EW) not shown...
  • Page 26 UNE DECHARGE ELECTRIQUE ENTRAINERA DES BLESSURES GRAVES OU LA MORT. WARNING 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 12142 Decal, ground...
  • Page 27 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 28 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 29: Generator Assembly 6 Kw

    6 KW GENERATOR ASSEMBLY ITEM NO. PART NO. DESCRIPTION 12736 Cover, generator box 12159 Capacitor, 25 uF marathon 15695 Capacitor, 45 uF marathon 16556 Generator, 6 kW 60Hz capacitor 12327 Case cover, marathon 6kw pancake 15241 Mount, compression 15045B Mount, generator 12328 Bearing, marathon 6kw pancake 12329...

  • Page 30: Generator Assembly 8 Kw

    8 KW GENERATOR ASSEMBLY ITEM NO. PART NO. DESCRIPTION 12736 Cover, generator box 16395 Clamp, capacitor 15695 Capacitor, generator 45 uF (oval) 16421 Fan, machined 60410 Screw, M8 x 16 60029 Washer, lock M8 16123 Plate, drive 11336 Screw, 3/8 - 24 x 7/8 15493 Diode, rotor 15492...

  • Page 31: Generator Assembly 8 Kw With Voltage Regulation

    GENERATOR ASSEMBLY - 8 KW WITH VOLTAGE REGULATION ITEM NO. PART NO. DESCRIPTION 12736 Cover, generator box 18556 Regulator, voltage - SE 350 12023 Generator, 10 kW 60 Hz regulated 11597B Bracket, gen mount 15241 Compression mount, engine...

  • Page 32: Manual Winch Mast Assembly

    MANUAL WINCH MAST ASSEMBLY...
  • Page 33 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 34: Electric Winch Mast Assembly

    ELECTRIC WINCH MAST ASSEMBLY...
  • Page 35 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 36: Enclosure Assembly

    ENCLOSURE ASSEMBLY...
  • Page 37 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 12252B Weldment, light storage 12605 Door latch SS, T-style 12251B Weldment, light storage...

  • Page 38: Frame Assembly

    FRAME ASSEMBLY...
  • Page 39 ITEM NO. PART NO. DESCRIPTION 11725B Weldment, fuel tank strap 12259 Tube, fuel pick up, 24 in. 15142 Fitting, .250NPT x .312 hose barb 16271 Fitting, .250NPT x .188 hose barb 12162 Tank, fuel - 56 gallon poly 13616B Strap, fuel tank 12080 Cap, fuel tank vent 3.50 dia.
  • Page 40 ITEM NO. PART NO. DESCRIPTION 11280 Spring, axle 11278 Tie plate, spring 11279 Nut, locking 12207 Axle, 3500 lb. 56SC 68.5TC 15540 Wheel, P205X75R15 radial w/rim 60096 Lug Nut, .500-20 (incl. w/axle) 11555B Weldment, removable tongue - 74” 11253 Cap, grease - axis with rubber plug 3500# 11254 Plug, grease cap - for zerk (Axis)

  • Page 41: Mast Junction Box Assembly, Quick Disconnect Lights

    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 42: Mast Junction Box Assembly, Hard Wired Lights

    MAST JUNCTION BOX ASSEMBLY - HARD WIRED 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 15864 Strain relief, .500NPT water tight 12095B Bracket, junction box...

  • Page 43: 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 44: Mitsubishi Engine

    MITSUBISHI ENGINE 31, 32...
  • Page 45 ITEM NO. PART NO. DESCRIPTION 16540 Radiator w/fan guard, Mitsubishi 16554B Weldment, engine mount - LH 16553B Weldment, engine mount - RH 13046 Engine, Mitsubishi - L3E int. Tier IV 16444 Element, air filter 16551B Bracket, air cleaner 16443 Filter, air with bracket 12838B Bracket, fuel filter/pump 16687...

  • Page 46: Kubota Engine

    KUBOTA ENGINE...
  • Page 47 SEE NOTE Thermostat assy, (not shown) *NOTE: Some Kubota engine parts are serial number specific. Please contact Kubota Engine America Corp. or the Magnum Products Technical Service Department at 1-800-926-9768 for information regarding engine parts. OPTIONAL FEATURES: 60774 Valve, drain 22MM-1.5 w/nipple 12227 Hose, oil drain .375 X 20, 30R7...

  • Page 48: Control Box And Panel Assembly

    CONTROL PANEL ASSEMBLY ITEM NO. PART NO. DESCRIPTION 65851 Breaker, main 30A, screw term 14249 Switch, toggle 15A 65325 Light, indicator (ballast) 65388 Light, indicator (main breaker) 15195 Switch, engine 16694 Indicator, glow plug - Mitsubishi only 15085 Gauge, hourmeter 65849 Breaker, 20A, 120V, 1-pole, push button 14130...
  • Page 49 CONTROL BOX ASSEMBLY ITEM NO. PART NO. DESCRIPTION 14202 Strain relief - .375 Romex w/nut 10241 Clamp, 2.50 - manual holder 11121 Tube, black manual holder, 14" 14257B Box, control 14201 Relay, 15 second fixed time delay, 10 Amp 65850 Breaker, 10A, 240V, I-pole, push button 14203 Block, terminal - 10 pos.

  • Page 50: Light Assembly

    LIGHT ASSEMBLY...

  • Page 51: Wiring Diagrams

    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 52: Metal Halide Ballast Box Assembly

    METAL HALIDE BALLAST BOX ASSEMBLY WARNING Do not mix metal halide and high pressure sodium ballast parts. Equipment damage or personal injury may result. ITEM NO. PART NO. DESCRIPTION 11079 Cover, ballast box 14679 Capacitor, metal halide 11166 Transformer, metal halide 14158 Block, terminal 11078...

  • Page 53: High Pressure Sodium Ballast Box Assembly

    HIGH PRESSURE SODIUM BALLAST BOX ASSEMBLY - OPTIONAL WARNING Do not mix metal halide and high pressure sodium ballast parts. Equipment damage or personal injury may result. ITEM NO. PART NO. DESCRIPTION 11079 Cover, ballast box 14782 Capacitor, sodium light 14783 Ignitor, sodium light 11167...
  • Page 54 AC CIRCUIT WIRING DIAGRAM - MODEL 5060...
  • Page 55 AC CIRCUIT WIRING DIAGRAM - MODEL 5080 (4 LIGHT)
  • Page 56 AC CIRCUIT WIRING DIAGRAM - MODEL 5080 (6 LIGHT)
  • Page 57 DC CIRCUIT WIRING DIAGRAM - MITSUBISHI ENGINE...
  • Page 58 DC CIRCUIT WIRING DIAGRAM - KUBOTA ENGINE...
  • Page 59 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 60 TRAILER LIGHTS WIRING...
  • Page 61 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 62 MAST JUNCTION BOX WIRING...
  • Page 64 REV: R PART NO: 16859 08.27.08...

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