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Magnum IAI9SE User Manual

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LIGHT TOWER
MLT3060 • MLT3080
OPERATING/PARTS MANUAL

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Summary of Contents for Magnum IAI9SE

  • Page 1 LIGHT TOWER MLT3060 • MLT3080 OPERATING/PARTS MANUAL...

  • Page 2: Introduction

    INTRODUCTION This manual provides information and procedures to safely operate and maintain the engine and generator. For your own safety and protection from physical injury, carefully read, understand and observe the safety instructions described in this manual. The information contained in this manual was based on machines in production at the time of publication.

  • 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 REPORTING TRAILER SAFETY DEFECTS ..................6 UNIT SERIAL NUMBER LOCATIONS ....................7 SAFETY SYMBOL SUMMARY ......................

  • 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

    • NEVER use tower if insulation on electrical cord is cut or worn through. • NEVER operate lights without protective lens cover in place or with a lens cover that is cracked or damaged! 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.

  • Page 6: Towing Safety

    • NEVER service electrical components if clothing or skin is wet. If the unit is stored outside, check the engine and generator for any moisture and dry the unit before use. • NEVER wash the unit with a power washer or high pressure hose. •...

  • Page 7: Unit Serial Number Locations

    UNIT SERIAL NUMBER LOCATIONS Unit I.D. Tag V.I.N. Tag Located on inside DATE OF MFG: MANUFACTURED BY/FABRIQUE PAR: COLD INFL. PRESS./PRESS. DE GONF A FROID GVWR/PNBV: of panel GAWR/PNBE TIRE/PNEU RIM/JANTE KPA(PSI/LPC) SGL/DUAL Refer to the locations illustrated below to find the unit ID tag, and trailer THIS VIEHICLE CONFORS TO ALL APPLICABLE STANDARDS PRESCRIBED UNDER THE CANADIAN MOTOR VIEHICLE SAFETY REGULATIONS IN ECCEFT ON THE DATE OF MANUFACTURE.

  • Page 8: Specifications

    SPECIFICATIONS Read this manual carefully before attempting to use this light tower. The potential for property damage, personal injury or death exists if this equipment is misused or installed incorrectly. 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.
  • Page 9 SPECIFICATIONS Read this manual carefully before attempting to use this light tower. The potential for property damage, personal injury or death exists if this equipment is misused or installed incorrectly. 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.
  • Page 10 SPECIFICATIONS Read this manual carefully before attempting to use this light tower. The potential for property damage, personal injury or death exists if this equipment is misused or installed incorrectly. 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.
  • Page 11 SPECIFICATIONS Read this manual carefully before attempting to use this light tower. The potential for property damage, personal injury or death exists if this equipment is misused or installed incorrectly. 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.

  • 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.

  • Page 14: Raising The Tower With The Optional Electric Winch

    RAISING THE TOWER WITH THE OPTIONAL ELECTRIC WINCH 1. Set up and level the trailer as described on page 12, and follow steps 1-3 on page 13. 2. Remove the safety pin from the mast lock bar (R). 3. Press the lower winch control toggle switch upward to raise mast DETAIL R 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

    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 MAIN BREAKER 240V breaker for the lights (2) to ON “I”, one at a time. BALLAST INDICATOR LIGHTS 3.

  • Page 18: Shutting Down

    SHUTTING DOWN When you have finished using the light tower proceed with shut down as follows: 1. Remove any loads from the auxiliary outlets. GLOW PLUG 2. Switch the individual circuit breakers for each light to the OFF “O” position. START 3.

  • Page 19: Removing The Lights For Transportation

    4. Release the mast lock bar by pulling the safety pin on the mast lock and pulling the lock bar free. Lower the mast by holding the lower winch control toggle switch to the right until the mast is resting in the transport cradle. Note: If the lock bar does not pull free, activate lower winch slightly to relieve pressure on the mast lock bar.

  • Page 20: Lifting The Trailer

    LIFTING THE TRAILER When lifting the light tower and trailer, attach any slings, chains or hooks directly to the central lifting eye. The lifting eye is located on the mast between the two forklift pockets. 1. Make sure the equipment being used to lift the light tower UPPER has sufficient capacity.

  • Page 21: Engine Maintenance

    ENGINE MAINTENANCE The periodic maintenance schedule below lists basic maintenance intervals for the engine. For detailed maintenance procedures refer to the engine operators manual. A copy of this manual was supplied with the unit when it was shipped from the factory. For additional or replacement copies of the engine operators manual, contact an authorized engine dealer in your area.

  • Page 22: Troubleshooting The Lights

    TROUBLESHOOTING THE LIGHTS WARNING HIGH VOLTAGE! THIS UNIT USES HIGH VOLTAGE CIRCUITS CAPABLE OF CAUSING SERIOUS INJURY OR DEATH. ONLY A QUALIFIED ELECTRICIAN SHOULD TROU- BLESHOOT OR REPAIR ELECTRICAL PROBLEMS OCCURRING IN THIS EQUIPMENT. MAST LIGHTS OFF BUT BALLAST INDICATORS ON CONTROL PANEL ARE ON: 1.

  • Page 23: Unit Decals

    UNIT DECALS WARNING SECURE MAST IN TRANSPORT LOCK BEFORE LIFTING OR TOWING! WARNUNG DEN MAST VOR DEM ANHEBEN ODER ABSCHLEPPEN IN DER TRANSPORTHALTERUNG SICHERN! ADVERTENCIA FIJE EL MASTIL EN LA TRABA DE TRANSPORTE ANTES DE REMOLCAR O LEVANTAR EL MISMO. ADVERTISSEMENT VERROUILLEZ SOLIDEMENT LE MAT POUR LE TRANSPORT AVANT DE...
  • Page 24 UNIT DECALS WARNING SECURE MAST IN TRANSPORT LOCK BEFORE LIFTING OR TOWING! WARNUNG DEN MAST VOR DEM ANHEBEN ODER ABSCHLEPPEN IN DER TRANSPORTHALTERUNG SICHERN! ADVERTENCIA FIJE EL MASTIL EN LA TRABA DE TRANSPORTE ANTES DE REMOLCAR O LEVANTAR EL MISMO. ADVERTISSEMENT VERROUILLEZ SOLIDEMENT LE MAT POUR LE TRANSPORT AVANT DE...
  • Page 25 UNIT DECALS DANGER ELECTRICAL STORAGE DEVICE WITHIN. CONTACT A QUALIFIED ELECTRICIAN FOR SERVICE OR TO OPEN ELECTRICAL BOX. ELECTRIC SHOCK WILL CAUSE SERIOUS INJURY OR DEATH. GEFAHR DANGER ENTHÄLT ELEKTRISCHES SPEICHERGERÄT. ZUR WARTUNG ODER ZUM ÖFFNEN DES ELEKTROGEHÄUSES EINEN GESCHULTEN ELEKTRIKER ZU RATE ZIEHEN.
  • Page 26 UNIT DECALS WARNING DANGER GEFHAR PELIGRO DANGER DO NOT SET UP UNIT IN HIGH WIND OR STELLEN SIE NICHT MASSEINHEIT IM STARKEN WIND ODER WÄHREND DER ELEKTRISCHEN ¡CNO INSTALE LA UNIDAD EN FUERTE VIENTO N'INSTALLEZ PAS L'UNITÉ EN FORT VENT OU DURING ELECTRICAL STORMS! O DURANTE TORMENTAS ELÉCTRICAS! PENDANT LES ORAGES ÉLECTRIQUES !
  • Page 27 ITEM PART DESCRIPTION NOTES 12140 Decal set, common mast 4-lang. 12141 Decal set, engine/electrical safety 4-lang. 11553 Decal, instruction - 3000 4 lang End S#0900186 10588 Decal, instruction - 3000 oval 4 lang Start S#0900187 - for manual winch models 12881 Decal, instruction - 3000 4 lang End S#0900186...

  • Page 28: Manual Winch Mast Assembly

    MANUAL WINCH MAST ASSEMBLY...
  • Page 29 ITEM PART DESCRIPTION NOTES 11954 Coil cord, mast 16600 Winch, manual 60584 Nut, .750-10 nylock G5 yellow zinc 11902B Weldment, mast tube 11649Z Weldment, t-bolt 15292 Screw, .750-10x6.500 hx hd SS 15380 Pin, cotter -.125x1.250 14262 Sheave, 3 in. 60247 Washer, flat .750 14234 Pin, clevis .500 x 2.00...

  • Page 30: Electric Winch Mast Assembly

    ELECTRIC WINCH MAST ASSEMBLY...
  • Page 31 ITEM PART DESCRIPTION NOTES 11954 Coil cord 12875B Cover, winch contactor 11293 Contactor, electric winch - warn 65049 Relay, 12V 30/40A N.O. w/diode 65707 Switch, toggle - spring weatherproof 12872B Bracket, winch mounting 12874 Winch, electric - 770 lb. hoist 15380 Pin, cotter - .125x1.250 15006...

  • Page 32: Frame And Components

    FRAME AND COMPONENTS...
  • Page 33 ITEM PART DESCRIPTION NOTES 11065B Bracket, fuel tank support 12080 Cap, fuel tank vented - 3.5” 11054 Tank, fuel 30 gal. 11057B Weldment, mast post 14845B Spring, kickback - 50 lb. 14261 Sheave - 2 in. 15015 Pin, clevis - .500 dia. X 1.250 11682 Jack, top wind - 2000 lb.

  • Page 34: Main Enclosure Components

    METAL ENCLOSURE COMPONENTS...
  • Page 35 ITEM PART DESCRIPTION NOTES 16560 Fender, plastic -13” tire 12014W Panel, side (R) 11066W Panel, door 11095 Hinge, continuous - 43.00 12344Z Weldment, cradle - common mast 16099 Assembly, mast cradle pin 11935 Pad, rubber - 2.00 X 2.00 X 1.00 11096W Panel, radiator access 11062W...

  • Page 36: Mitsubishi Engine Assembly

    MITSUBISHI ENGINE ASSEMBLY 31,32 Note: Engine and generator parts used in all Magnum Products LLC equipment carry the Original Equipment Manufacturer (OEM) warranty unless otherwise stated. OEM warranty parts must be purchased through an OEM dealer. Please contact Magnum Products LLC with questions.
  • Page 37 ITEM PART DESCRIPTION NOTES 16540 Radiator w/fan guard End S#0900191 13924 Radiator w/fan guard - welded Start S#0900192 16554B Weldment, engine mount - LH 16553B Weldment, engine mount - RH 16597 Engine, Mitsubishi L3E-W261ML End S#081484 13046 Engine, Mitsubishi - L3E int. Tier IV Start S#081485 16444 Element, air filter...

  • Page 38: Kubota Engine Assembly

    KUBOTA ENGINE ASSEMBLY Note: Engine and generator parts used in all Magnum Products LLC equipment carry the Original Equipment Manufacturer (OEM) warranty unless otherwise stated. OEM warranty parts must be purchased through an OEM dealer. Please contact Magnum Products LLC with questions.
  • Page 39 ITEM PART DESCRIPTION NOTES 16540 Radiator w/fan guard End S#0900191 13924 Radiator w/fan guard - welded Start S#0900192 12338B Weldment, engine mount 12286 Engine, Kubota D905 MLT3060 13281 Engine, Kubota D1105 MLT 3080 16444 Element, air filter 13483B Weldment, filter bracket 16687 Hose, radiator upper 12350...

  • Page 40: Control Panel Assembly

    CONTROL PANEL ASSEMBLY ITEM NO.PART NO. DESCRIPTION NOTES 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 Receptacle, 120V/20A GFI (5-20R) UL...

  • Page 41: Control Box Assembly

    CONTROL BOX ASSEMBLY ITEM PART DESCRIPTION NOTES 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, 10A 65850 Breaker, 10A, 240V, I-pole, push button 14203 Block, terminal - 10 pos.

  • Page 42: Oval Light Assembly

    OVAL LIGHT ASSEMBLY...
  • Page 43 ITEM PART DESCRIPTION NOTES 60304 Screw, M5 x 25 pan hd phillips 60447 Nut, M5 nylock 13367 Assembly, aluminum ring 13369 Lens, glass oval 13373 Gasket, lens oval 11391 Bulb, 1000W MH short length 13399 Screw, M4 x 18 pan hd phillips 60067 Washer, #10 flat .435/.060 SS 13370...

  • Page 44: Rectangular Light Assembly

    RECTANGULAR LIGHT ASSEMBLY...
  • Page 45 ITEM PART DESCRIPTION NOTES 11393 Cover, Magnum light 61059 Screw, 10-32X1 slot hex w/flange SS 11303 Lens, Magnum rectangular light 11392 Clip, glass Magnum light 11398 Support, bulb Magnum light 11391 Bulb - 1000W MH short length 11465 Bulb - 1000W HPS short length 11394 Socket, Magnum light 11460...

  • Page 46: Round Light Assembly

    ROUND LIGHT ASSEMBLY WARNING Do not mix metal halide and high pressure sodium bulbs or parts. Equipment damage or personal injury may result.
  • Page 47 ITEM PART DESCRIPTION NOTES 15864 Connector, cord 15971 Housing, aluminum 15392Z Weldment, lamp level arm 14632 Yoke, light 12794Z Weldment, wing nut - extended light 14166 Cord, quick disconnect (optional) 14634 Cord, hard wired light 14730 Socket, light 16758 Reflector, aluminum 16499 Gasket, hood 16272...

  • Page 48: Spore Rectangular Light Assembly

    SPERO RECTANGULAR LIGHT ASSEMBLY...
  • Page 49 ITEM PART DESCRIPTION NOTES 12800 Gasket, lens - extruded light 12802 Lens, extruded light 12801 Support, bulb - extruded light 11391 Bulb - 1000W MH short length 11394 Socket, Magnum light 12809 Reflector, extruded light 12794B Weldment, wing nut - extruded light 12796B Weldment, bracket - trunnion 12803...

  • Page 50: Mast Junction Box Assembly - Quick Disconnect Lights

    MAST JUNCTION BOX ASSEMBLY - QUICK DISCONNECT LIGHTS ITEM PART DESCRIPTION NOTES 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 12095B...

  • Page 51: Mast Junction Box Assembly - Hard Wired Lights

    MAST JUNCTION BOX ASSEMBLY - HARD WIRED LIGHTS ITEM PART DESCRIPTION NOTES 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 16143...

  • Page 52: Metal Halide Ballast Box Assembly

    METAL HALIDE BALLAST BOX ASSEMBLY WARNING DO NOT mix metal halide and high pressure sodium ballast parts! ITEM PART DESCRIPTION NOTES 11079 Cover, ballast box 14679 Capacitor, metal halide 11166 Transformer, metal halide 10227 Assembly, transformer & cap set 14158 Block, terminal 11078 Box, ballast...

  • Page 53: High Pressure Sodium Ballast Box Assembly

    HIGH PRESSURE SODIUM BALLAST BOX ASSEMBLY WARNING DO NOT mix high pressure sodium and metal halide ballast parts! ITEM PART DESCRIPTION NOTES 11079 Cover, ballast box 14782 Capacitor, sodium light 14783 Ignitor, sodium light 11167 Transformer, sodium light 11168 Assembly, transformer & cap set 14158 Block, terminal 11078...

  • Page 54: Kw Generator Assembly

    6 KW GENERATOR ASSEMBLY ITEM PART DESCRIPTION NOTES 12736 Marathon gen box cover, 6KW-20KW 16395 Capacitor clamp 12159 Capacitor, 25 uF Marathon 6KW 15695 Capacitor, 45uF Marathon 16556 Generator, 6 kW 60Hz capacitor 12327 Marathon 6KW pancake case cover 15241 Compression mount, engine/generator 15045 Generator mounting bar...

  • Page 55: Kw Generator Assembly

    8 KW GENERATOR ASSEMBLY ITEM PART DESCRIPTION NOTES 12736 Cover, generator box 16395 Capacitor clamp 15695 Capacitor, generator 45 uF 15798 Capacitor, 50uF, 440VAC, 50/60 Hz 15212 Generator, 8kw 60 Hz capacitor End SN: 0900431 10486 Generator, 8kw, cap regulated Start SN: 0900432 11338 Generator end cover...

  • Page 56: Ac Wiring Diagram - Mlt3060

    AC WIRING DIAGRAM - MLT3060...

  • Page 57: Ac Wiring Diagram - Mlt3080

    AC WIRING DIAGRAM - MLT3080...

  • Page 58: Dc Wiring Diagram - Mitsubishi

    DC WIRING DIAGRAM - MITSUBISHI...

  • Page 59: Dc Wiring Diagram - Kubota

    DC WIRING DIAGRAM - KUBOTA End S#0900090...

  • Page 60: Dc Wiring Diagram - Kubota

    DC WIRING DIAGRAM - KUBOTA Start S#0900091...

  • Page 61: Dc Circuit Wiring Diagram - Dual Electric Winch

    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 62: Mast Junction Box Wiring

    MAST JUNCTION BOX WIRING...
  • Page 64 REV: W PART NO: 11132 06.25.09...

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