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GNUM

PRODUCTS LLC

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NIGHTBUSTER LIGHT TOWER

MODELS MLT3060 & MLT3080

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OPERATORS MANUAL / PARTS BOOK

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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. THE INFORMATlON CON
TAINED IN THIS MANUAL WAS BASED ON MACHINES IN PRODUCTION AT THE TIME OF
PUBLlCATION. MAGNUM PRODUCTS LLC RESERVES THE RIGHT TO CHANGE ANY POR
TION OF THIS INFORMATION WITHOUT NOTICE.
An 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.

MAGNUM 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 #

TABLE OF 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 PANEL ASSEMBlY
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 11
PAGE 12
PAGE 12
PAGE 13
PAGE 13
PAGE 14
PAGE 14
PAGE 14
PAGE 15
PAGE 15
PAGE 16
PAGE 17
PAGES 18 - 21
PAGES22-23
PAGES24-25
PAGES26-27
PAGES28-29
PAGES 30 - 31
PAGES32 -33
PAGE34
PAGE35
PAGE36
PAGE 37
PAGE38
PAGE39
PAGE40
PAGE41
PAGES42 -43
PAGES4445
PAGE46
PAGE47

SAFETY NOTES

Ths manual contains NOTES, CAUTIONS and WARNINGS which must be followed to prevent !he
possibility 01 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

SiCil1~-:
~--_.--

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[I!i!i~--,

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li!!L____-=:J

OPERATlNG SAFETY
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 properuse of 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 SAFETY
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 of 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.

TOWING SAFETY
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. Contact your 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.
Connectsafety chains 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 10 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 TRAllER SAFETY DEFECTS

1I 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 il 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 SAFETY
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 clothing or skin s wet. 1I 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.

SPECIFlCAnoNS
Engine manufacturer
Engine model
Enginetype
Engine horsepower (standby)
Engine horsepower (primed)
Fuel tank capacity
Fue! consumption

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)

Engine manufacturer
Engine model
Enginetype
Engine horsepower (primad)
Fuel tank capacity
Fuel consumption

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)

Generator manufacturer
Generator modal
Generator output (kW)
Generalor output (kVA)
Generator frequency
Generator output voltage
Generator output (amperes)
Generator power factor
Generator insulation

Maralhon Electric
332CSA5214
6.0
6.0
60Hz
1201240V, single phase
50-25
1.0
Class .p

Ughting type
Ballast type
Lumens
Coverage (approximate)

Metal halide or high pressure sodium

Coil & core
440,000
5-7 acres (20,235-28,329 sq. meters)

Maximum height of tower

Length wilh mas! stowed
Width
Width with outriggers extended
Height
Weight with fual

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)

r
LlGHT TOWER SET UP

REAR
JACK

GROUNDING
STUD
TONGUE
JACK

BlOCKTHE

~L--------"T;:;RAILER WHEElS

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 on lirm ground Ihal is relatively flat. This will make it easier lo levelthe 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

RAISING THE TOWER

JUNCTION BOX

LlGHT

AOJUSTMENT
HARDWARE

MAST

WINCHI~~-J~~~~
MAST
LOCK

MAST
CABLE

roNGUE
WlNCH

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!
The 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 01 cables lor excessive wear or damage. Make sure the cables are properly centered in
each pulley.
4. Check the electrical coil cord tor 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).

E
9

RAISING THE TOWER (continued)

6. Afterthe Mas! is 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 01 the lower sections gets stuck, STOP IMMEDI
ATELY and contact an authorized service center. DO NOT
EXTENO THE MAST BEVOND THE COLOREO MARK ON THE
MAST TUBE (H).

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.

10

9
1. MAIN 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.

11

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).

0000

WARNINGI
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

=lrr
OFF

CAUTION! Do not crank the engine longer than 10 seconds at a time. If the englnE 111 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

LlGHT OPERAnON

1. Once the engine is up to temperature and running

smoothly, switch main circuit breaker (1) to the on
"1" position.
2. With main circuit breaker on, switch each individual
circuit breaker for the lights (2) lo on "1", one al a time.
3. The ballast indicator IIghts (3) will come on
,

$
momentarily as the lights strike. As the lights warm
up, the ballast indicator lights will continue to get
brighler and Ihen remain on. This confirms that
power is coming frcm Ihe ballests to the lights.
4. If an indicator light does not come on, the ballast
may need to be serviced. If the indicator light
comes on and stays lit bul Ihe relatad light is not
iIIuminatad, check the bulb.
F-'
.:::I::~!!
'i'
'l'
5. The lights require a warm up periad of 5-15 minutes
before they reach full oulput. If Ihe lights are shut
down, they require a cool-clown period of 10 minutes before they can be switched on again.
6. The light tower uses four 1000W bulbs. When checking or replacing the bulbs, wipe them with a clean
clolh to avoid leaving any grease, 011 residue or fingerprints on the glass. Any residue can create a ho!
spot on the bulb, causing premature bulb failure.

-.

G"=..=__

WARNING!
NEVER OPERATE THE UGHT5 WITHOUT THE PROTECTlVE LEN5
COVER OR WITH A LEN5 COVER THAT 15 CRACKED OR DAMAGED!
The bulbs In the IIght fixtures produce high temperatures and oparate
under pressure. A broken or missing lens cover eould cause the bulbs
to shatter, causing injury.

WARNING!
Bulbs become extremely hot in use! Allow bulb fixture to eool 10-15
minutes before handling.

AUXILIARY OUTLETS
The control panel is equipped with two outlets for running
accessories or tools from the generator. Power is supplied
to Ihe ouUets any time the engine ls runnlng and the main
circuit breaker is switched on "1", Note: Do not pu/l more
than 1OOOW {roro each outlet when the lights are on. This
will overload !he generator and cause the majn circuit
breaker to trip. Should the breaker lrip, switch off the lights,
remove some of the load lO the outlets and wait 10 minutes
for the bu lbs to cool before tuming them back on.
With all of Ihe lights off, lhe full generator output may be
used with the optional 240V twist-Iock outlel.

13

120V GFCI OUTlET

(STANDARDk

'~,

240V TWIST-LOCK

OUTlET,.

(OPTIONAl) "~.

"

r
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 lO F (3-50 Cl increase in ambient air temperature over 72 F (22.20 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.

0000

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 01 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 01 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

TOWING THE TRAILER

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 re 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 TRAILER

When lifting the light tower and trailer, attach any slings, chains or hooks directly to the centrallifting 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
any damage to the unit. Make sure the mast winch handle or any other obstructions -, clear of the
forklift tines before lifting.

CENTRAL
LlFTING EYE--~

FORKLlFT
POCKETS

\
D

f~3~~~~~~~~
15

FORKLIFT
POCKETS

TROUBLESHOOTING THE LlGHTS

WARNINGI
HIGH VOLTAGE! 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 445 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 47 for eleclrical schematics.

16

DAILY INSPECTION
1. Inspect condition 01 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 MAINTENANCE
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.

Check lor fuel leaks.

Change engine oil.

Every

Every

Every

Every

Every

Every

50

100

200

400

500

800

Every
Two

hours

hours

hours

hours

hours

hours

years

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 50 hours of oparation.

17

OECAL LOCATIONS

ONENGINE
FANGUARD

INSIDE
DOOR
INSIDE
DOOA

18

DECAL LOCATIONS

ON GENERATOR
HOUSING

INSIDE
DOOR

19

oeCAL LOCATIONS

INSIDE ANO OUTSIDE

ABOVE EXHAUST PIPE

ABOVE RADIATOR (CAT ENGINE)

BELOW RADIATOR (MITSU,~E~N:::G:::IN:E:)~~-t!il
www.m-p-lIc.com

UNITSETUP

INSTRUCTION

OECAL

ABOVE

RADIATOR

CAP

NEXT TO GROUND
STUD

DECALLOCATlONS

ON MANUAL
HOLDER
ON TOP OF BALLAST
BOXES BOTH SIDES

ONTOPOF
_~~~~CONTROL BOX

ONTOPOF

CONTROLBOX

21

MANUALWI NCH MAST ASSEMBLY

11

MANUAL WINCH MAST ASSEMBLV

ITEM NO.

2
3
4
5
6
7
8
9
10

11
12
13
14
15
16
17
18
19
20
21

22
23
24
25

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

23

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)

FRAME ANO COMPONENTS

33

32~~

r1
4

14

40~
41/
42

31~

FRAME ANO COMPONENTS

ITEM NO.
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

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

25

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)

METALENCLOSURECOMPONENTS

10~
3
3---1

Q~

10

15

~@

18

16

19

20_~

26

11

METAL ENCLOSURE COMPONENTS

ITEM NO.
1
2

3
4
5
6
7
8
9

10
11

12
13
14
15
16
17
18
19
20
21

PART NO.

QTY

16560
11061W
11066W
11095
11091Z
15018Z
14797
11096W
11062W
15123
11060W
10224
10220
10219
65406
11097W
11098W
11077W
65407
14459B
14651

2
1
2
2
1
1
1

1
1

2
1
1
1

2
2
1
1
1
2
1
2

27

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)

CATERPILLAR ENGINE AND GENERATOR

19

A
I!

iC~

,~~~~~~;:

"

\~

"~~i!/'

'""~~:~,:::::::;/

U\~.>-~12

0'
11

CATERPILLAR ENGINE AND GENERATOR

ITEM NO.
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

PARTNO.
11165
11152B
16778
Page 41
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

QTV
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
1
3
1
1
1
1
1
1

29

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 12
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)

ENGINE ANO GENERATOR COMPONENTS

10

16

2~.

12~
tJ
~
~fJ>
:

17

~~15

~18

23
19

4
~. ______ 13

fJ>~

25

12

ITEMNO.

PARTNO.

1
2
3

16540
16554B
16553B

4
5
6
7
8
9

16597
Page 41
16551B
16552B

QTY
1
1
1
1

10
11

16589
16443

1
1
1
1
1
1

12
13

15241
15045B

4
1

14

16535B

15

14410

2
1

16687
16588

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 PAGE

30

ENGINE ANO GENERATOR COMPONENTS

ITEMNO.

PARTNO.

QTV

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

16724
19257
60501
19167
19301
16742
19219
22419B
16832
16686
15266
16677
16678
16683
16684
16689
16444
16445
16691
16692
16693
15074
15073
15695
15493
15492
15212
11148
11147
16134
16833
16743
16744
16745
11226
11228
11262
11209
11227
16874
11208
16730
16729

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

45

46
47
48
49
50
51
52
53
54
55
56
57
58

1
1
1
3
1
1
1
1

1
1
1

1
1
1
1
1
1

1
1
1

31

DESCRIPTION

Guard, fan
Fitting, oil drain
Elbow, 45 deg.
Hose, oil drain
Cap, oH drain
Fan, engine
Cap, radiator
Bracket, overflow bottle
Head, fuel filter
Element, fuel filler
Muffler, engina (nol shown)
Switch, oil pressure (not shown)
Switch, temperatura (not shown)
Solenoid, fuel (nol shown)
Kit, fuel feed (not shown)
Support, hosa (nol shown)
Element, air cleaner (not shown)
Brackel, air cleaner clamp (not shown)
Filler, o! (nol shown)
Belt, altamalor (nol shown)
Glow plug, engine (nol shown)
Cable, battery red 38" (nol shown)
Cable battery black 25" (nol shown)
Capacilor, generalor (not shown)
Diode, generator (nol shown)
Suppressor (nol shown)
Generator, 8 kW (nol shown, oplional)
Dip stick, engine oi! (nol shown)
Cap, oi! filler (not shown)
Bearing. generalor (nol shown)
Starter, angine Mitsubishi (nol shown)
Altemator, Mitsubishi (nol shown)
Water pump, Mitsubsh (nol shown)
Thermoslat, Milsubish (nol shown)
Push rod, engine Milsubishi (nol shown)
Lifter, engine Milsubishi (nol shown)
Injector, fuel wl seals (nol shown)
Gaskel, valve cover (nol shown)
Kil, engine gaskel (nol shown)
Hamess, engine eleclrieal (nol shown)
Manual, workshop Mitsubishi
Manual, engina parts Milsubishi
Manual, angine operation Milsubishi

CONTROL PANEL ASSEMBLY

CATERPILLAR ENGINE

C)

CJ

,/Cj

-12

11

ITEMNO.
1
2
3
4
5
6
7
8

9
10
11
12
13

PARTNO.
14248
14249
65325
65388
11176
11177
15085
14156
14130
14137
10081
16237
65415

QTY
1
4
4
1
1
1
1
1
1
1
1
1

32

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)

CONTROL PANEL ASSEMBLV

MITSUBISHI ENGINE

10

<~~.

'<

O"

&l

'.

""

/~,

\;)

:CJ.

12

11

ITEM NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14

PARTNO.
14248
14249
65325
65388
15195
16694
15085
14156
14130
14137
10081
10235
65415
16734

QTV

33

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 kW generator option)

CONTROL BOX ASSEMBLV

",

,~

/'

.I~
{
,
:~"'

~I
~

ITEM NO.
1

2
3
4

5
6
7

8
9

PARTNO.
14202
10241
11121
14257B
14201
14841
14203
14204
14219

~
I

QTV

5
1
1
1
1
1
2
1
2

34

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

HIGH PRESSURE SODIUM LlGHT ASSEMBLV

13

____ 3

WARNING!

DO NOT MIX HIGH PRESSURE

SOOIM ANO METAL HAUDE

BULBS OR PARTSI

ITEM NO.

PARTNO.

15864
15971
14632
14166
14634
14730
16758
16499
16272
14784
16761
16718
16750
16757
16759
16760

2
3
4
5
6
7
8
9

10
11

12
13
14
15
16

QTV
1
1
1
1
1
1
1
1
1
1
1
1
1
1

35

DESCRIPTlON
Connector, cord
Housng, alumnum
Yoke, light
Cord, quck dsconnect (optonal)
Cord, hard wred light
Socket, light
Reflector, aluminum
Gasket, hood
Ring, renforcement
Bulb, hgh pressure sodum
Support, bulb
Ring, clamp
Lens,lght
Assembly, cable
Fixture, complete (quick disconnect)
Fixture, complete (hard wired cord)

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

10
11

12
13
14
15
16

PARTNO.

15864
15971
14632
14166
14634
14730
16758
16499
16272
14217
16761
16718
16750
16757
16746
16747

QTV
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

QUICK DISCONNECT MAST JUNCTION BOX ASSEMBLV

1-

ITEM NO.
1

2
3
4
5

6
7

PARTNO.
14278
15863
15697
16394
15403
15404
15402

QTV

1
1

5
1
4
4

37

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

MAST JUNCTlON BOX ASSEMBLY

1-

2---_-&di

ITEM NO.

PARTNO.

1
2

14278
15863
15697
15861
16081
15217
15864

3
4
5
6
7

QTY
1
1
5
4
1
1
4

38

DESCRIPTlON
Cord, coil7-conductor
Strain relief, cord
Washer, rubber seal
Nut,lock
Junction box, mast
Strip, terminal
Strain relief. cord