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Multiquip MLT25 User's Manual

1. J3 46 1 1 10 WIRE COIL CORD BALLAST 1 49609 LAMP 1 24uF 480V 27 IN NEU OUTPUT RED 16 AWG BALLAST ASSEMBLY P N 29614 VOLTAGE SELECTOR VOLTAGE REG SWITCH ADJ SETTING POSITION 10 240 120V BLK YEL 16 AWG 120V IN BALLAST 2 24uFQ480V D 277V NEU OUTPUT 35 RED 16 AWG 7 2 1 RU 30 480 277V 1 1 1 1 1 NEUTRAL BUS LK YEL G TB1 3 E di 2 BALLAST 3 WHT 14 AWG VE 24uF 480V Oo BLK16AWG 277VIN NEU OUTPUT err RED 16 AWG E 71 WHT 14 AWG A OQO YEL 16 AWG BLKIYEL 16 AWG ci K 1 BALLAST 4 24uF 9480V YEL 16 AWG CAPACITOR 56 Cro YEL 16 AWG 1 1 1 1 1 NEU OUTPUT 1 1 RED SAWS Jf m FELIS AWG 1 YEL 16 AWG BLK YEL 16 AWG 120V IN c5 BALLAST 5 24uFQ480V CAPACITOR BLICIG AWG 277VIN NEU OUTPUT ORG 16 AWG YEL 16 AWG BLK YEL 16 AWG 120V IN BALLAST 6 24uF 480V CAPACITOR BLICIG AWG 277V IN NEU OUTPUT PURPLE 16 AWG YEL 16 AWG NOTES RESISTOR IS INTERNALLY WIRE COLOR CODE IS BASE COLOR STRIPE INSTALLED WITHIN THE CAPACITOR MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 PAGE 47
2. WIRING DIAGRAM SHEET 2 3 PRESENT K6 BRN BLUE 18 AWG 8 12 RED 18 AWG NO TRANSDUCER gt 6 5 6 Q 6 GND DC 4 5 AC IN NEU 30 8 0 10 VDC OUT 20 eo AC INPUT L3 1 9 GRAYBLUE 16AWG g eS 4 m WHT 16 AWG L GRAY 16 AWG WHT 16 AWG NEUTRAL BUS m 1 e 96 WHT 16 AWG Ld 0000 65 8 5 8 0 5 lt 3 2 14 T1 T2 T3 14 3 120V 30 277V 9 RED BLUE 16 AWG WHT 16 AWG RED 16 AWG 5 4 30 277V NOTES AN K1 CONTACTOR ABB AF09Z 22 00 20 A K2 K5 CONTACTORS ABB AF09Z 40 00 20 PROGRAMMABLE LOGIC CONTROLLER FOR REPLACEMENT CONTACT MQ PARTS DEPT A WIRE COLOR CODE IS BASE COLOR STRIPE It I2 A I3 9 10V IT 18 A I1 AI2 0 10V 12 24 VDC INPUT 8x DC ALS 3 22 v3 n L1 T1 3 2 4 30 120V 16 AWG n RED PINK 16 AWG GRAY RED 16 AWG TO CB1L2 SEE SHEET 1 BLK ORG 16 AWG TO CB1 4 GRAY BLUE 16 AWG SHEET1 7 BLK16 AWG SHIELD OIL PRESSURE GAUGE TERMINAL GROUND OIL PRESSURE GAUGE TERMINAL 4 IGNITION RED 16 AWG RED PAGE 48 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12
3. Slow down for bumps in the road Take your foot off the brake when crossing the bump B DO NOT brake while in a curve unless absolutely necessary Instead slow down before you enter the curve and power through the curve This way the towing vehicle remains in charge DO NOT apply the brakes to correct extreme trailer swaying Continued pulling of the trailer and even slight acceleration will provide a stabilizing force B Anticipate the trailer swaying Swaying is the trailer reaction to the air pressure wave caused by passing trucks and buses Continued pulling of the trailer provides a stabilizing force to correct swaying DO NOT apply the brakes to correct trailer swaying Use lower gear when driving down steep or long grades Use the engine and transmission as a brake Do not ride the brakes as they can overheat and become ineffective B Be aware of your trailer height especially when approaching roofed areas and around trees B Make regular stops about once each hour Confirm that Coupler is secure to the hitch and is locked Electrical connectors are secure There is appropriate slack in the safety chains There is appropriate slack in the breakaway switch pullpin cable Tires are not visibly low on pressure The following guidelines are intended to assist the operator in the operation and handling of a trailer Safety precautions should be followed at all times when operating a t
4. Connect and test electric brake operation Secure portable power cables in cable tray with tie wraps The maximum speed for highway towing is 55 MPH unless posted otherwise Recommended off road towing 15 not to exceed 15 MPH or less depending on type of terrain PAGE 8 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 SAFETY INFORMATION f lifting through pockets make sure forks of forklift are inserted in pockets as far as possible before lifting Never allow any person or animal to stand underneath the equipment while lifting DO NOT lift equipment to unnecessary heights Loading and Tie Down on Flatbed Truck NOTICE When loading onto flatbed truck make sure that front jackstand of light tower is retracted and in the horizontal position so that the foot does not make contact with the deck floor FRONT JACKSTAND RETRACTED E PE B TRANSPORT TIE DOWN TONGUE Make sure that the two side left and right and two rear jackstands are in the vertical postion slightly extended so that each foot makes contact with the deck floor Straps and chains should be routed through the transport tie down points located beneath each corner of the cabinet to allow even application of forece to the front and rear of the machine DO NOT secure the unit by running a strap or chain over the tongue of the light tower This may cause sever
5. License Light This light illuminates the license plate Whenever towing of the light tower is required make sure this light is operational Brake Lights Before towing the light tower make sure that these lights are operational and are working correctly Never tow the light tower if these lights are inoperative Engine Exhaust Pipe Directs engine exhaust to the rear of the light tower NEVER block this exhaust pipe with obstructions ALWAYS place the generator in an area free of obstructions Tires This light tower uses ST205 75D15 LR C size tire Replace with only recommended tire size Never tow light tower with bad or worn tires Circuit Breakers 3 Pole 15 A Turn the lamps on and off 19 20 21 22 23 24 Tongue Jackstand Use this jackstand to support the tongue when attaching the light tower to a towing vehicle Safety Chain Always attach safety chain to the towing vehicle Never tow the light tower with the safety chain unattached Ball Hitch Coupler Attach this coupler to the towing vehicle Use only the specified ball diameter as indicated on your coupler Use of any other ball diameter will create an extremely dangerous condition which can result in separation of the coupler and ball or ball failure Vertical Mast Winch Use this winch to raise the mast to the vertical position Mast Lock Release Pin Pull this pin to start placing the tower mast
6. The trailer VIN Tag contains the following critical safety information for the use of your trailer GAWR The maximum gross weight that an axle cansupport It is the lowest of axle wheel or tire rating Usually the tire or wheel rating is lower than the axle rating and determines GAWR GVWR The maximum allowable gross weight of the trailer and its contents The gross weight of the trailer includes the weight of the trailer and all of the items within it GVWR is sometimes referred to as GTWR Gross Trailer Weight Rating or MGTW Maximum Gross Trailer Weight GVWR GTWR and MGTW are all the same rating The sum total of the GAWR for all trailer axles may be less than the GVWR for the trailer because some of the trailer load is to be carried by the tow vehicle rather than by the trailer axle s The total weight of the cargo and trailer must not exceed the GVWR and the load on an axle must not exceed its GAWR PSIC The tire pressure psi measured when cold VIN The Vehicle Identification Number EMPTY WEIGHT Some information that comes with the trailer such as the Manufacturer s Statement of Origin is not a reliable source for empty or net weight The shipping documents list average or standard weights and your trailer may be equipped with options PAGE 30 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 SAFETY GUIDELINES TRAILERS BALL HITCH COUPLER A ball hitch coupler F
7. the spindle nut by hand Do not turn the hub while the spindle nut is loose Install a new cotter pin through the spindle nut and axle Checkthe adjustments Both the hub and the spindle nut should be able to move freely the spindle nut motion will be limited by the cotter pin DANGER NEVER crawl under the trailer unless it is on firm and level ground and resting on properly placed and secured jackstands The possibility exists of the trailer falling thus causing equipment damage and severe bodily harm even death DANGER When performing trailer inspection and maintenance activities you must jack up the trailer using jacks and jackstands When jacking and using jackstands place them so as to clear wiring brake lines and suspension parts i e springs torsion bars Place jacks and jackstands inside of the perimeter strip on the supporting structure to which the axles are attached PAGE 26 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 SAFETY GUIDELINES TRAILERS Shift your automatic transmission into a lower gear for city driving ALWAYS use lower gears for climbing and descending grades DO NOT ride the brakes while descending grades they may get so hot that they stop working Then you will potentially have a runaway tow vehicle and trailer To conserve fuel don t use full throttle to climb a hill Instead build speed on the approach
8. with the road the ball andcoupler system All bent or broken coupler parts must be replaced before towing the trailer THE TOW VEHICLE PINTLE HITCH AND PINTLE COUPLER MUST HAVE A RATED TOWING CAPACITY EQUAL TO OR GREATER THAN THE TRAILER Gross Vehicle Weight Rating GVWR ITIS ESSENTIAL THAT THE PINTLE HITCH BE OF THE SAME SIZE AS THE PINTLE COUPLER The coupler size and load rating capacity are marked on the coupler Hitch capacity is marked on the hitch Coupler to hitch mismatch can result in uncoupling leading to death or serious injury Be sure the LOAD RATING of the pintle hitch hook is equal or greater than the load rating of the pintle eye coupler Be sure the SIZE of the pintle hitch hook matches the size of the pintle eye coupler A worn cracked or corroded pintle hitch hook can fail while towing and may result in death or serious injury Before coupling trailer inspect the pintle hitch hook for Wear corrosion and cracks Replace worn or damaged pintle hitch hook Rock the pintle eye coupler to make sure it is secured tightly to the hitch Wipe the inside and outside of the pintle coupler Clean and inspect it visually for cracks and deformations Feel the inside of the coupler for worn spots and pits Be sure the coupler is secured tightly to the tongue of the trailer All coupler fasteners must be visibly solid against the trailer frame E Raise the bottom surface of the co
9. 1 1 1 LICENSE RED TAIL LIGHT LEFT 6 PINMOLDED 1 6 PIN MOLDED TAIL LIGHT AUXILIARY CONNECTOR i CONNECTOR LIGHTS RIGHT TURN TAIL LIGHT 1 1 CHASSIS RIGHT STOP GROUND TAIL LIGHT TAIL CLEARANCE 8 LICENSE PLATE BROWN BROWN 1 GROUND TOW VEHICLE WHITE ABS BLACK CONTRO BOX BLUE 4 ABS POWER SUPPLY BLUE TAIL LIGI YELLOW 5 LEFT TURN SIGNAL HAZZARD YELLO RED STOP LAMP RED P 1 CONNECTOR TRAILER SIDE l TOWING VEHICLE SIDE TAIL LIGHT LEFT TURN TAIL LIGHT Figure M Trailer to Tow Vehicle Wiring Diagram MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 PAGE 41 TROUBLESHOOTING Table 5 Lamp Troubleshooting Possible Cause Solution Test the lamp in a fixture which is operating properly 2 Famppured out Replace if necessary Inspect lamp base to see if there is arcing at center Lamp Loose in Socket contact button Tighten lamp snugly Check socket for damage Replace if defective Lamp Plugs Not Tight Check plug and receptacle Tighten if loose Interchange ballast plugs in generator enclosure If lamp starts replace ballast Check ballast wiring against diagram Check for swollen capacitor charred wiring core and coil or other signs of excessive heat Check line voltage at ballast input Volt
10. 5 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 PAGE 9 OPERATION MANUAL HERE S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON HAND WHEN CALLING MQ Parts Department 800 427 1244 Fax 800 672 7877 310 537 3700 Fax 310 637 3284 Warranty Department 800 421 1244 Fax 310 943 2249 310 537 3700 UNITED KINGDOM Multiquip UK Limited Head Office Tel 800 421 1244 Fax 310 537 3927 Fax 310 537 4259 Fax 310 943 2238 UNITED STATES Multiquip Corporate Office 18910 Wilmington Ave Carson CA 90746 Contact mg multiquip com Service Department 800 421 1244 310 537 3700 Technical Assistance 800 478 1244 MEXICO MQ Cipsa Carr Fed Mexico Puebla KM 126 5 Momoxpan Cholula Puebla 72760 Mexico Contact pmastretta cipsa com mx Tel 0161 339 2223 Fax 0161 339 3226 Tel 52 222 225 9900 Fax 52 222 285 0420 Unit 2 Northpoint Industrial Estate Globe Lane Dukinfield Cheshire SK16 4UJ Contact sales multiquip co uk CANADA Multiquip 4110 Industriel Boul Laval Quebec Canada H7L 6V3 Contact jmartin multiquip com Tel 450 625 2244 Tel 877 963 4411 Fax 450 625 8664 COPYRIGHT 2012 MULTIQUIP INC Multiquip Inc the MQ logo are registered trademarks of Multiquip Inc and may not be used reproduced or altered without written permission All other trademarks are the property of their respective owners and
11. Always use an adequate tow vehicle and hitch If the vehicle or hitch is not properly selected and matched to the Gross Vehicle Weight Rating GVWR of your trailer you can cause an accident that could lead to death or serious injury If you already have a tow vehicle know your vehicle tow rating and make certain the trailer s rated capacity is less than or equal to the tow vehicle s rated towing capacity If you already have or plan to buy a trailer make certain that the tow rating of the tow vehicle is equal to or greater than that of the trailer The trailer VIN tag contains the critical safetyinformation PAGE 28 MLT25 SERIES LIGHT TOWER OPERATION MANUAL 40 11 28 12 SAFETY GUIDELINES TRAILERS Drive slowly at first 5 mph or so and turn the wheel to get the feel of how the tow vehicle and trailer combination responds Next make some right and left hand turns Watch in your side mirrors to see how the trailer follows the tow vehicle Turning with a trailer attached requires more room Stop the rig a few times from speeds no greater than 10 mph If your trailer is equipped with brakes try using different combinations of trailer brake and tow vehicle brake Note the effect that the trailer brakes have when they are the only brakes used When properly adjusted the trailer brakes will come on just before the tow vehicle brakes It will take practice to learn how to back up a tow vehicle with a trailer
12. attached Take it slow Before backing up get out of the tow vehicle and look behind the trailer to make sure that there are no obstacles Some drivers place their hands at the bottom of the steering wheel and while the tow vehicle is in reverse think of the hands as being on the top of the wheel When the hands move to the right counterclockwise as you would do to turn the tow vehicle to the left when moving forward the rear of the trailer moves to the right Conversely rotating the steering wheel clockwise with your hands at the bottom of the wheel will move the rear of the trailer to the left while backing up If you are towing a bumper hitch rig be careful not to allow the trailer to turn too much because it will hit the rear of the tow vehicle To straighten the rig either pull forward or turn the steering wheel in the opposite direction TRAILER VIN TAG Figure A below is a sample of the Vehicle Identification Number VIN Tag which is typically located on the left front of the trailer See Figure B for location WTR JABE LAbE LEY BEN ED 30 HEA V JERE Y LONLE2 COWL VEL ICYBEO AEKLN DN BEGTENENL DEO AEHICNFE DN EM DYLE DE e COVEOBING 10 VIT YbbICYBTE bEECCBIBED LHE SOS AEHICTE 2VEELA BECRTWLIOM I OH LHE DYLE OE WWMNEVCLILE CE AEHICNFE EHICFE COMLOBW2 LO VIT YbbICYBT
13. in the vertical position When tower mast has reached full vertical position insert pin to keep mast from falling Tie Down Points Used to tie down light tower with strap or chains to allow even application of force to the front and rear of the equipment during transport MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 PAGE 15 13 16 17 18 INSPECTION DANGER ALWAYS make sure the area above light tower is open and clear of overhead power lines and other obstructions The tower extends in excess of 30 ft 9 meters Contact with overhead power lines or other obstructions could result in equipment damage serious injury or death i amp power cables have been plugged into the appropriate receptacles J1 J6 on the T Bar assembly Follow instructions below to correctly install the power cable plugs a Locate the 6 key lock 3 pin female connectors on the T bar See Figure 4 FRONT MAST RAISED FEMALE CONNECTORS LOCKING NUT MALE CONNECTOR Figure 4 T Bar and Cable Connectors BEFORE STARTING 1 Read all safety instructions at the beginning of manual 2 Clean the light tower removing dirt and dust particularly the engine cooling air inlet and air cleaner 3 Check the ai
14. light tower is on level ground before use so that it cannot slide or shift around endangering workers Always keep immediate area free of bystanders ALWAYS make sure trailer is leveled with all outriggers extended before raising tower Outriggers must remain extended while tower is up AL WAYS keep area behind trailer clear of people while raising and lowering mast NEVER remove safety pin or pull mast locking pin while tower is in a raised position CHECK the mast and winch cables for wear If problem occurs when lowering or raising the tower STOP immediately Contact a trained technician for assistance NEVER pivot or retract mast while unit is operating NEVER use the light tower mast as a crane DO NOT lift anything with the mast NEVER attach anything to the light tower mast unless it is an authorized Multiquip component ALWAYS lowerthe light tower when not in use or if high winds or electrical storms are expected MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 PAGE 7 SAFETY INFORMATION Avoid sudden stops and starts This can cause skidding or jack knifing Smooth gradual starts and stops will improve towing Avoid sharp turns to prevent rolling Trailer should be adjusted to a level position at all times when towing Raise and lock trailer wheel stand in up position when towing B Place chock blocks underneath wheel to prev
15. the location of the nearest 1 S fire extinguisher B ALWAYS know the location of the nearest first aid kit ALWAYS know the location of the nearest phone or keep a phone on the job site Also know the phone numbers of the nearest ambulance doctor and fire department This information will be invaluable in the case of an emergency GENERAL SAFETY NEVER operate this equipment without proper protective clothing shatterproof glasses respiratory protection hearing protection steel toed boots and other protective devices required by the job or city and state regulations 090090 NEVER operate this equipment when not feeling well due to fatigue illness or when under medication NEVER operate this equipment under the influence of drugs or alcohol ALWAYS check the equipment for loosened threads or bolts before starting DO NOT use the equipment for any purpose other than its intended purposes or applications PAGE 6 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 SAFETY INFORMATION NOTICE ALWAYS keep the immediate area surrounding the light tower clean neat and free of debris ALWAYS keep the machine in proper running condition Fix damage to machine and replace any broken parts immediately ALWAYS store equipment properly when it is not being used Equipment should be stored in a clean dry location out of the reach of children a
16. tires same axle Brake components loose Reslace components Locking Brakes bent or broken p Brake drums out of round Noisy Brakes Brake components correct Replace and correct Brake lining thickness Install new shoes and incorrect or not adjusted Es Dragging correctly linings Brakes Enough brake fluid or correct Replace rubber parts fluid fill with dot 4 fluid ADJUSTABLE CHANNEL Your trailer may be equipped with an adjustable channel Figure 16 that allows the coupler to be raised or lowered to a desired height Periodically check the channel bolts for damage or loosening NOTICE When replacing channel mounting hardware nuts bolts and washers never substitute substandard hardware Pay close attention to bolt length and grade ALWAYS use manufacturer s recommended parts when replacing channel mounting hardware MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 PAGE 25 MAINTENANCE TRAILERS DANGER Improper weld repair will lead to early failure of the trailer structure and can cause serious injury or death DO NOT repair cracked or broken welds unless you have a certified welder perform the repair If not have the welds repaired by your dealer If the trailer is involved in an accident have it inspected immediately by qualified personnel In addition the trailer should be inspected annually for signs of wear or deformations LEAF SUSPENSION The leaf
17. used with permission This manual MUST accompany the equipment at all times This manual is considered a permanent part of the equipment and should remain with the unit if resold The information and specifications included in this publication were in effect at the time of approval for printing Illustrations descriptions references and technical data contained in this manual are for guidance only and may not be considered as binding Multiquip Inc reserves the right to discontinue or change specifications design or the information published in this publication at any time without notice and without incurring any obligations Your Local Dealer is MULTIQUIP
18. 14 Hydraulic Brake Components HYDRAULIC BRAKE ACTUATOR The hydraulic brake actuator Figure 15 is the mechanism that activates the trailers brake system This actuator changes fluid power into mechanical power Therefore the fluid level must be checked frequently to assure that the brakes function properly HYDRAULIC BRAKE FLUID RESERVOIR Figure 15 Hydraulic Brake Actuator The following trailer maintenance guidelines are intended to assist the operator in preventive maintenance TRAILER BRAKES Properly functioning brake shoes and drums are essential to ensure safety The brakes should be inspected the first 200 miles of operation This will allow the brake shoes and drums to seat properly After the first 200 mile interval inspect the brakes every 3 000 miles If driving over rough terrain inspect the brakes more frequently HYDRAULIC BRAKES your trailer has hydraulic brakes they function the same way the surge brakes do on your tow vehicle The hydraulic braking system must be inspected at least as often as the brakes on the tow vehicle but no less than once per year This inspection includes an assessment of the condition and proper operation of the wheel cylinders brake shoes brake drums and hubs MANUALLY ADJUSTING THE BRAKES Most axles are fitted with a brake mechanism that will adjust the brakes during a hard stop However some braking systems are not automatically adjusted by ha
19. 19 OPERATION 1 With the mast in the deployed position vertical unscrew the mast rotation locking knob to release the mast for rotation 2 Grip the mast rotation handles and rotate the mast until the lamps are facing the desired direction 3 When the lamps are facing the desired direction tighten the mast rotation lock knob to lock the mast in place TURNING ON THE LAMPS Three lamp circuit breakers 15 amps each are located on the front of the light tower to turn the lamps on and off The lamps can be turned on with the voltage selector in three different positions See Table 3 for the different settings Table 3 Lamp Settings Circuit Lamps Breaker ON ON Voltage Selector Switch Setting Voltage Regulator Setting 1 PHASE 240 120 7 208V 2 83 CB2 4 5 amp 6 me a Te l 1 Before turning on the lamps make sure that main circuit breaker on the generator control panel and the circuit breakers shown in Figure 8 are all in the off position 240V CB1 CB2 CB3 Figure 8 Lamp Circuit Breakers Raising the Mast Once the tower mast has been locked into its vertical position the mast can now be raised The tower allows the lamps to be extended upwards in excess of 30 feet Refer to Figure 7 for location of components 1 Turn the mast extension winch clockwise and observe that the mast begins to extend upwards 2 Continue turning the winch in the clockwise dire
20. 25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 PAGE 37 SAFETY GUIDELINES TRAILERS M S The M S or M S indicates that the tire has some mud and snow capability Most radial tires have these markings hence they have some mud and snow capability Speed Rating The speed rating denotes the speed at which a tire is designed to be driven for extended periods of time The ratings range from 99 miles per hour mph to 186 mph These ratings are listed in Table A Note You may not find this information on all tires because it is not required by law Table A Speed Rating a m v 0 v mm U S DOT Tire Identification Number This begins with the letters DOT and indicates that the tire meets all federal standards The next two numbers or letters are the plant code where it was manufactured and the last four numbers represent the week and year the tire was built For example the numbers 3197 means the 31st week of 1997 The other numbers are marketing codes used at the manufacturer s discretion This information is used to contact consumers if a tire defect requires a recall Tire Ply Composition and Materials Used The number of plies indicates the number of layers of rubber coated fabric in the tire In general the greater the number of plies the more weight a tire can support Tire manufacturers also must indicate the material
21. 431 cm ZEE INE Length Mast Deployed Position 101 in 256 cm PAGE 12 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 GENERAL INFORMATION STABILITY The light tower can be raised vertically in excess of 31 5 feet 9 6 meters by means of a manual winch The tower tensioning system is designed to provide the necessary tension to safely control the pivot of the tower The light tower has a wind stability of up to 65 mph with outriggers and jackstands fully deployed PANEL LIGHT A panel light automatically illuminates the control panel and all functions when the engine access door is opened This feature is convenient for night deployment TRAILER DESIGN The trailer design of the MLT25 Series light tower withstands the rigors of the jobsite in addition to providing smooth highway towing The Multiquip MLT25 Series Light Tower is a dedicated general purpose light tower engineered to provide dependable lighting for a wide range of applications This includes lighting for construction sites industrial locations special events and emergency conditions METAL HALIDE LAMPS The lighting system of the MLT25 Series Light Tower is comprised of 6 metal halide 1000 watt lamps These lamps provide maximum illumination with typical li
22. AY RED 14 AWG SEE SHEET 2 GREEN 10 AWG L1 L2 131 NEU GND L GROUND STUD 3 POLE 15 K2 NO 3 POLE FUSE CIRCUIT BREAKER CB1 HOLDER e 1 Lil m SSS 1 1 BLK 14AWG 44 AWG KNO X 15 AMP aN K1 NC F2 RED 14 AWG RED WHT 14 AWG R3 yR4 RED YEL 14 AWG 15 AMP 12 BLUE 14 AWG BLUE WHT 14 AWG VOLTAGE TRANSDUCER GRAY BLUE 14 AWG AC INPUT PIN 1 L3 SEE SHEET 2 3 POLE 15 AMP 3 POLE FUSE CIRCUIT BREAKER CB2 I oe 1 L311 4 BRN 14AWG AIN BRN WHT 14AWG O O 3 15 LTN K3 NO F5 ORG 14 AWG ORG WHT 14 AWG 09 Ti 15 Ti 6 YEL 14 AWG YEL WHT 14 AWG 0 O 15 T Ge REUS T2 0 3 POLE 15 AMP NO 3 POLE FUSE CIRCUIT BREAKER 083 B 0 1 12 F7 BLK 14 AWG PURPLE WHT 14 AWG 15 AMP SINGLE PHASE 5 SFB PINK WHT 14 AWG 3 15 ANF9 SPARE 4 lt 3 0 ZTN PAGE 46 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 WIRING DIAGRAM SHEET 1 T BAR ASSEMBLY PIN 49796
23. C AIR GUN TORQUE WRENCH Figure L Wheel Lug Nuts Tightening Sequence Table B below will help pinpoint the causes and solutions of tire wear problems Table B Tire Wear Troubleshooting es Adjust pressure to particular Adjust pressure to particular Edge Weal j Under inflation load per tire manufacturer Make sure load does not Loss of camber Side Wear exceed axle rating or overloading Align wheels Check bearing adjustment Flat Spots Wheel lockup and Avoid sudden stops when rt tire skidding possible and adjust brakes ALWAYS wear safety glasses when removing or installing force fitted parts DO NOT attempt to repair or modify a wheel DO NOT install an inner tube to correct a leak through through the rim If the rim is cracked the air pressure in the inner tube may cause pieces of the rim to explode break off with great force and cause serious eye or bodily injury Wheel Rims the trailer has been struck or impacted on or near the wheels or if the trailer has struck a curb inspect the rims for damage i e being out of round and replace any damaged wheel Inspect the wheels for damage every year even if no obvious impact has occurred Wheels Bearings and Lug Nuts A loose worn or damaged wheel bearing is the most common cause of brakes that grab To check wheel bearings jack trailer and check wheels for side to side looseness If the wheels are loose or sp
24. E 12 EEDEENT 8 IH EEEECL LHE DYLE Ok WWMRENCEME CHOMMVBCAE DE COMET M VATED BHBE CHYONE kel Tg lIBE2lbMER NEYCANHED V EVBHIGQIE DUE Figure A Vehicle VIN Tag INOPERABLE BRAKES LIGHTS OR MIRRORS Be sure that the brakes and all of the lights on your trailer are functioning properly before towing your trailer Check the trailer taillights by turning on your tow vehicle headlights Check the trailer brake lights by having someone step on the tow vehicle brake pedal while you look at trailer lights Do the same thing to check the turn signal lights See Trailer Wiring Diagram section in this manual Standard mirrors usually do not provide adequate visibility for viewing traffic to the sides and rear of a towed trailer You must provide mirrors that allow you to safely observe approaching traffic Improper electrical connection between the tow vehicle and the trailer will result in inoperable lights and can lead to collision Before each tow check that the tail lights brake lights and turn signals work TRAILER TOWING TIPS Driving a vehicle with a trailer in tow is vastly different from driving the same vehicle without a trailer in tow Acceleration maneuverability and braking are all diminished with a trailer in tow It takes longer to get up to speed you need more room to turn and pass and more distance
25. ES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 PAGE 3 TABLE OF CONTENTS MLT25 Series Light Tower Proposition 65 Warning 2 Reporting Safety 3 Table Of 4 Safety Information es 5 110 Specifications RAE ONU REEL E 11 DimensionS ee 12 General Information es 13 Components es 14 15 Inspection 16 17 Operation eenia 18 21 MaintenancCe pe 22 23 Maintenance Trailers 24 26 Safety Guidelines Trailers 27 41 Troubleshooting aue 42 44 Electronic Components Locator 45 Wiring 46 48 Specifications are subject to change without notice PAGE 4 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 SAFETY INFORMATION SAFETY SYMBOLS Potential hazards associated with the operation of this equipment will be referenced with hazard symbols which may appear throughout this manual in conjunction with safety messages Symbol Safety Hazard MH Burn hazards Explosive fuel hazards Electric shock hazards Do not operate or service the equipment before reading the entire manual Safety precautions should be followed at all times when operating this equipmen
26. IMPORTANT SAFETY CHAIN CROSS BOTH MASTER LINK SAFETY CHAINS Figure E Attaching Safety Chain Ball Hitch TRAILER 2 TONGUE Loop around a frame member of the tow vehicle or holes provided in the hitch system DO NOT attach them to an interchangeable part of the hitch assembly Have enough slack to permit tight turns but not be close to the road surface so if the trailer uncouples the safety chains can hold the tongue up above the road Improper rigging of the safety chains can result in loss of control of the trailer and tow vehicle leading to death or serious injury if the trailer uncouples from the tow vehicle Fasten chains to frame of tow vehicle DO NOT fasten chains to any part of the hitch unless the hitch has holes or loops specifically for that purpose Cross chains underneath hitch and coupler with enough slack to permit turning and to hold tongue up if the trailer comes loose MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 PAGE 33 SAFETY GUIDELINES TRAILERS PINTLE HITCH COUPLER A pintle eye coupler Figure G connects to a pintle hook hitch that is located on or under the rear bumper of the tow vehicle This system of coupling a trailer to a tow vehicle is sometimes referred to as a lunette eye tow ring or G I hitch Figure G Pintle Hitch Coupler A pintle hitch trailer may be fitted with a tongue jackstand that can raise and lower the coupler
27. If additional work items hoses tools clamps etc are going to be added to the trailer be sure they are distributed evenly to prevent overloading front to back and side to side Heavy items should be placed low and as close to the axle positions as reasonable Too many items on one side may overload a tire Excessive loads and or underinflation cause tire overloading and as a result abnormal tire flexing occurs This situation can generate an excessive amount of heat within the tire Excessive heat may lead to tire failure It is the air pressure that enables a tire to support the load so proper inflation is critical The proper air pressure may be found on the certification VIN label and or on the Tire and Loading Information placard This value should never exceed the maximum cold inflation pressure stamped on the tire Perform the following steps to determine the load limit of your trailer Step 1 Locate the statement The weight of cargo should never exceed XXX kg or XXX lbs on your vehicle s Tire and Loading Information placard Figure This value equals the available amount of equipment load capacity Step 2 Determine the weight of the equipment being loaded on the tow vehicle That weight may not safely exceed the available equipment load capacity The trailer s Tire Information Placard is attached adjacent to or near the trailer s VIN Certification label at the left front of the trailer See Figure MLT
28. OPERATION MANUAL MULTIQUIP MODEL MLT25 SERIES DEDICATED LIGHT TOWER Revision 0 11 28 12 To find the latest revision of this publication visit our website at www multiquip com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES PN 49808 PROPOSITION 65 WARNING CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm PAGE 2 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 REPORTING SAFETY DEFECTS If you believe that your vehicle has a defect that could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying Multiquip at 1 800 421 1244 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 However NHTSA cannot become involved in individual problems between you your dealer or Multiquip To contact NHTSA you may either call the Vehicle Safety Hotline toll free at 1 888 327 4236 1 800 424 9153 go to http www nhtsa dot gov or write to Administrator NHTSA 1200 New Jersey Avenue S E Washington DC 20590 You can also obtain information about motor vehicle safety from http www safecar gov MLT25 SERI
29. R OPERATION MANUAL REV 0 11 28 12 PAGE 27 SAFETY GUIDELINES TRAILERS for the use of your trailer Again be sure your hitch and tow vehicle are rated for the Gross Vehicle Weight Rating of your trailer DRIVING CONDITIONS When towing a trailer you will have decreased acceleration Proper selection and condition of the coupler and hitch are essential to safely towing your trailer A loss of coupling may result in death or serious injury Be sure the hitch load rating is equal to or greater than the load rating of the coupler Be sure the hitch size matches the coupler size Observe the hitch for wear corrosion and cracks before coupling Replace worn corroded or cracked hitch components before coupling the trailer to the tow vehicle Be sure the hitch components are tight before coupling the trailer to the tow vehicle An improperly coupled trailer can result in death or serious injury DO NOT move the trailer until The coupler is secured and locked to hitch The safety chains are secured to the tow vehicle The trailer jack s are fully retracted DO NOT tow the trailer on the road until Tires and wheels are checked The trailer brakes are checked The breakaway switch is connected to the tow vehicle The load is secured to the trailer The trailer lights are connected and checked Use of a hitch with a load rating less than the load rating of the trailer can re
30. The tongue jack is mounted to the A frame front or tongue part of the trailer By rotating the jack handle clockwise the jack will extend and raise the tongue of the trailer The load rating of the coupler and the necessary pintle hitch size are listed on the trailer tongue You must provide a pintle hitch and pintle coupler for your tow vehicle where the load rating of the pintle hitch and pintle coupler is equal to or greater than that of your trailer Also the pintle hitch size must be the same as the pintle coupler size If the hitch is too small too large underrated loose or worn the trailer can come loose from the tow vehicle and may cause death or serious injury Pintle Coupler and Pintle Hook Before each tow check the locking device that secures the coupler to the pintle hook assembly The pintle hook lever must be able to operate freely and automatically snap into place into the latched position Lightly oil the pivot points and sliding surfaces with motor oil to prevent rust and help ensure proper operation of the latching mechanism If you see or feel evidence of wear such as flat spots deformations pitting or corrosion on the pintle hook or coupler immediately have your dealer inspect them to determine the proper action to prevent possible failure of Connecting Trailer Lights Connect the trailer lights to the tow vehicle s electrical system using the electric connectors at the front of t
31. This information indicates the maximum load and tire pressure when the tire is used as a dual that is when four tires are put on each rear axle a total of six or more tires on the vehicle Max Load Single kg lbs at kPa psi Cold This information indicates the maximum load and tire pressure when the tire is used as a single MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 PAGE 9 SAFETY GUIDELINES TRAILERS NOTICE NEVER use an pneumatic air gun to tighten wheel lug nuts Over tightening lug nuts will result in breaking the studs permanently deforming the mounting stud holes in the wheels Lug nuts are prone to loosen after initial installation which can lead to death or serious injury Check all wheel lug nuts periodically Lug Nut Torque Requirements Itis extremely important to apply and maintain proper wheel mounting torque on the trailer Be sure to use only the fasteners matched to the cone angle of the wheel Proper procedure for attachment of the wheels is as follows 1 Start all wheel lug nuts by hand 2 Torque all lug nuts in sequence See Figure L DO NOT torque the wheel lug nuts all the way down Tighten each lug nut in 3 separate passes as defined by Table C 3 Check to see if the lug nuts are tight after the first 10 25 and 50 miles of driving and before each tow thereafter 4 LUG NUTS 6 06 NUTS 8 LUG NUTS LUG NUTS x PNEUMATI
32. ad rating of the hitch and ball is equal to or greater than that of your trailer Also the ball size must be the same as the coupler size If the hitch ball is too small too large is underrated is loose EMERGENCY FLARES ANDTRIANGLE REFLECTORS It is wise to carry these warning devices even if you are not towing a trailer It is particularly important to have these when towing a trailer because the hazard flashers of your towing vehicle will not operate for as long a period of time when the battery is running both the trailer lights and tow vehicle lights SAFETY CHAINS If the coupler connection comes loose the safety chains can keep the trailer attached to the tow vehicle With properly rigged safety chains it is possible to keep the tongue of the trailer from digging into the road pavement even if the coupler to hitch connection comes apart TRAILER LIGHTING AND BRAKING CONNECTOR A device that connects electrical power from the tow vehicle to the trailer Electricity is used to turn on brake lights running lights and turn signals as required In addition if your trailer has a separate braking system the electrical connector will also supply power to the brakes from the tow vehicle BREAKAWAY SYSTEM If the trailer coupler connection comes loose the breakaway system can actuate emergency hydraulic brakes depending on the type of actuator on the trailer The breakaway cable must be rigged to the tow vehicle with appropria
33. age should be within 10 of nameplate rating when operating at normal load Increase supply voltage or remove external load Lamp will not start Proper HID lamps will perform erratically or fail to start on an improper ballast The ballast nameplate Defective Ballast Low Voltage data must agree with the line voltage and lamp used Improper ballast causes lamp failure Note Mercury lamps of the same wattage will operate properly on Metal Halide ballasts Improper Ballast Operating position should agree with the lamp tech A BU HOR lamp can be operated base up vertical to Improper Lamp Operating and including the horizontal and a BD can be operated Position Metal Halide only base down vertical to approaching but not including the horizontal A lamp operated beyond the specified position may not start HID lamps High Pressure Sodium Metal Halide Lamp has been Operating Cool Mercury Vapor require from 4 to 8 minutes cool down Down Time Insufficient time before restarting Switch off breaker and allow lamp to cool Improper ballasting can cause flickering or erratic Improper Ballast operation In the start up period the lamp may ignite Lamp flickers and goes start to warm up and then extinguish cycle out intermittent or Under certain conditions new lamps may cycle cycling New Lamp Usually after 3 tries to start at 30 to 60 second intervals lamps will stabilize and operate satisfactorily Defective Lam
34. al to or greater than the load rating of the trailer you intend to tow The hitch capacity must also be matched to the tow vehicle capacity Your vehicle dealer can provide and install the proper hitch on your tow vehicle SUSPENSION SYSTEM Sway bars shock absorbers heavy duty springs heavy duty tires and other suspension components may be required to sufficiently tow the trailer and pump BRAKE CONTROLLER For trailers equipped with electric brakes the electric brake controller is part of the tow vehicle and is essential in the operation of the electric brakes on the trailer The brake controller is not the same as the safety breakaway brake system that may be equipped on the trailer SIDE VIEW MIRRORS The size of the trailer that is being towed and your state law regulations determine the size of the mirrors However some states prohibit extended mirrors on a tow vehicle except while a trailer is actually being towed In this situation detachable extended mirrors are necessary Check with your dealer or the appropriate state agency for mirror requirements HEAVY DUTY FLASHER A Heavy Duty Flasher is an electrical component that may be required when your trailer turn signal lights are attached to the tow vehicle flasher circuit ELECTRICAL CONNECTOR An Electrical Connector connects the light and brake systems on the trailer to the light and brake controls on the towing vehicle VIN TAG Figure B VIN Tag Location
35. alf of the left road side of the unit This certification VIN label will indicate the trailers Gross Vehicle Weight Rating GVWR This is the most weight the fully loaded trailer can weigh It will also provide the Gross Axle Weight Rating GAWR This is the most a the axle can weigh TIRE SAFETY Unsafe Tires Lug Nuts or Wheels Trailer tires and wheels are more likely to fail than car tires and wheels because they carry a heavier load Therefore it is essential to inspect the trailer tires before each tow If a tire has a bald spot bulge cuts is showing any cords or is cracked replace the tire before towing If a tire has uneven tread wear take the trailer to a dealer service center for diagnosis Uneven tread wear can be caused by tire imbalance axle misalignment or incorrect inflation Tires with too little tread will not provide adequate tracking on wet roadways and can result in loss of control leading to death or serious injury Improper tire pressure causes an unstable trailer and can result in a tire blowout and loss of control Therefore before each tow you must also check the tire pressure Tire pressure must be checked when tires are cold Allow 3 hours cool down after driving as much as 1 mile at 40 mph before checking tire pressure Trailer tires will be inflated to higher pressures than passenger vehicle tires Since trailer wheels and lug nuts or bolts are subjected to greater side loads than automobil
36. are under water for a long period of time wheel bearings may fail If this is the case service wheel bearings immediately The possibility exists of the wheels falling off causing equipment damage and severe bodily harm even death If the trailer has not been used for an extended amount of time have the bearings inspected and packed more frequently at least every six months and prior to use Follow the steps below to disassemble the wheel hub and service the wheel bearings See Figure 17 BEARING 0 BEARING SPINDLE NUT Figure 17 Wheel Hub Components Failure to maintain proper fluid level in the actuator may result in loss of braking action which could cause severe property damage injury or death Periodically check the actuator mounting fasteners for damage or loosening Inspect the actuator for worn or damaged parts As you are towing your trailer be aware of any changes in braking quality This could be an early warning of brake or actuator malfunction and requires immediate attention Consult a certified brake specialist to make necessary adjustment or repairs Table 4 Hydraulic Brake Troubleshooting Symptom Possible Cause Brake line broken or kinked Repair or replace Brake lining glazed Reburnish or replace Trailer overloaded Correct weight No Brakes Weak Brakes or Brake drums scored or Mach One Side Inflate all tires equally Tir on th es unmatched Match
37. corresponding male connector locate the key tab B as shown in Figure 5 d Align the key tab B on the male connector with the key slot A on the female connector and press together until seated Secure the connector by screwing the knurled locking nut of the male connector to the threaded portion of the female connector to ensure good contact between the two connectors MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 PAGE 17 OPERATION STARTING THE ENGINE NOTICE Refer to the accompanying DCA25SSIU3 generator operation and parts manual Part Number 49810 for information on how to start the engine MAST OPERATION DANGER ALWAYS make sure the area above light tower is open and clear of overhead power lines and other obstructions The tower extends in excess of 30 feet 9 meters Contact with overhead power lines or other obstructions could result in equipment damage serious injury Figure 6 Deploying Outriggers or death 2 As soon as the pin clears the travel position hole release it and continue sliding out the outrigger The pin must snap into the outrigger locking hole in the DO NOT stand behind extended position the trailer while the mast 15 being raised or lowered Serious injury could result if the mast falls down 3 After extending all outriggers rotate all trailer jack stands into the foot down position then turn the crank handle on the jackstand
38. ction until the desired height has been reached 3 Release the winch This winch is of the self locking type The tension on the cable will keep the mast in place Lowering the Mast 1 Turn the mast extension winch counterclockwise and observe that the mast begins to lower 2 Continue turning the winch counterclockwise until the mast has been fully retracted slack in the cable Stowing the Mast to Horizontal Position Refer to Figure 7 for the location of components 1 Remove the mast lock release pin to allow the mast section to be lowered to the horizontal position Pull out the mast lock handle to unlatch 2 Turn the vertical mast winch counterclockwise and observe that mast begins to approach the horizontal position The mast lock handle can now be released 3 Continue turning the vertical mast winch in the counterclockwise direction As the mast approaches the mast cradle support pull the retaining pin and then the cradle lock release pin to allow the mast to rest in the cradle 4 Once the mast is resting in the mast cradle support insert the cradle lock release pin and secure with retaining pin to keep mast in place Rotating the Mast To change the direction that the lamps are facing the mast can be rotated Refer to Figure 7 for the location of components PAGE 20 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 OPERATION FRONT MAST RAISED Figur
39. e damage to the unit TRANSPORTING SAFETY Before lifting make sure that light tower parts are not damaged and screws are not loosened or lost ALWAYS make sure crane or lifting device has been properly secured to lifting hook of the equipment NEVER lift the equipment while engine is running Make sure the tower is in the stowed position before lifting STOWED POSITION B ALWAYS Make sure rear mast lock is secure before lifting Use adequate lifting cable wire or rope of sufficient strength Use one point suspension hook and lift straight upwards LIFTING BALE 1 LIGHT TOWER FORKLIFT POCKETS Q MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 PAGE 9 SAFETY INFORMATION ELECTRICAL SAFETY NEVER operate light tower or handle any electrical equipment while standing in water while barefoot while hands are wet or in the rain A dangerous electrical shock could occur causing severe bodily harm or even death ALWAYS make sure the area above the light tower is open and clear of overhead power lines and other obstructions The tower extends in excess of 30 feet 9 meters Contact with
40. e 11 Lamp Orientation When the lamps turn on check the AC voltmeter reading and adjust the Voltage Regulator knob if necessary to correct the voltage If any of the lamps do not turn on as they should refer to the troubleshooting section of this manual Close all cabinet doors after desired lights are on NOTICE NEVER operate the light tower with the engine compartment doors open Operation with the doors open may cause insufficient cooling to the unit and damage may result 2 Move the Voltage Selector Figure 9 to the desired position 3 PHASE 240 139 PRESS TO LOCK Figure 9 Voltage Selector Positions 3 Adjust the Voltage Regulator Knob to the corresponding voltage noted in Table 3 Check the AC voltmeter for the correct reading See Figure 10 INCREASE DECREASE AC Voltmeter Voltage Regulator Figure 10 Voltage Regulator Knob and AC Voltmeter 4 Switch the appropriate circuit breakers to the ON position for the lamps Figure 11 that you want to turn on in the selected Voltage Selector setting as detailed in Table 3 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 PAGE 21 MAINTENANCE SERVICING THE MAST RAISE LOWER CABLE SYSTEM To replace any components in the mast raise lower cable system use the following steps See Figure 12 MAST PULLEY CABLE SHEAVE Figure 12 Mast Raise Lower Cable System 1 Lower the mast to the horizontal r
41. e wheels they are more prone to loosen Before each tow check to make sure they are tight The proper tightness torque for lug nuts is listed in the lug nut tightening section of this manual Use a torque wrench to tighten the lug nuts If you do not have a torque wrench use a lug wrench from your tow vehicle and tighten the nuts as much as you can Then have a service garage or trailer dealer tighten the lug nuts to the proper torque Metal creep between the wheel rim and lug nuts will cause rim to loosen and could result in a wheel coming off leading to death or serious injury Tighten lug nuts before each tow PAGE 36 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 SAFETY GUIDELINES TRAILERS Determining Load Limit of Tow Vehicle Step 1 Locate the statement The combined weight of occupants and cargo should never exceed lbs on your vehicle s placard Step 2 Determine the combined weight of the driver and passengers who will be riding in your vehicle Step 3 Subtract the combined weight of the driver and passengers from XXX kilograms or XXX pounds Step 4 The resulting figure equals the available amount of cargo and luggage capacity For example if the XXX amount equals 1400 Ibs and there will be five 150 Ib passengers in your vehicle the amount of available cargo and luggage capacity is 650 Ibs 1400 750 5 150 650 Ibs Step 5 D
42. eeds to be replaced they should both be replaced at the same time 3 Disassemble the mast by disconnecting the cables from the mast and sliding the sections apart The lower cable can be disconnected from the winch The mast sections are heavy and awkward to handle Use proper lifting devices and procedures when servicing the mast and its components MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 PAGE 23 MAINTENANCE TRAILERS 6 Replace the adjusting hole cover 7 Repeat the above procedure on all brakes 8 Lower the trailer to the ground Check the fluid level in the master cylinder reservoir at least every three months If you tow your trailer an average of 1 000 miles per month in a hot and dry environment you must check the brake fluid level once a month The brake fluid reservoir is located on the tongue of the trailer Always fill with clean uncontaminated DOT 4 brake fluid Figure 14 below displays the major hydraulic brake components that will require inspection and maintenance Please inspect these components as required using steps 1 through 6 as referenced in the Manually Adjusting The Brakes section on this page See Table 4 for Hydraulic Brake Troubleshooting Anchor Post Hydraulic Wheel Retractor Springs Backing Plate OM Secondary Sx 20 Shoe 677 Adjuster Spring Primary Shoe Adjuster Assembly Figure
43. ekly during use to insure the maximum tire life and tread wear DO NOT bleed air from tires when they are hot E Inspect tires for uneven wear patterns on the tread cracks foreign objects or other signs of wear or trauma Remove bits of glass and foreign objects wedged in the tread Make sure your tire valves have valve caps ALWAYS check tire pressure on tow vehicle and trailer before towing Check tire pressure at least once a month DO NOT overload tow vehicle Check the tire information and loading placard for safe allowable tire loading conditions Tire Repair The proper repair of a punctured tire requires a plug for the hole and a patch for the area inside the tire that surrounds the puncture hole Punctures through the tread can be repaired if they are not too large but punctures to the sidewall should not be repaired Tires must be removed from the rim to be properly inspected before being plugged and patched Replacing Worn or Damaged Tires Replace the tire before towing the trailer if the tire treads have less than 1 16 inch depth or the telltale bands are visible Check inflation pressure weekly during use to insure the maximum tire life and tread wear A bubble cut or bulge in a side wall can result in a tire blowout Inspect both side walls of each tire for any bubble cut or bulge and replace a damaged tire before towing the trailer Uniform Tire Quality Grading Standards UTQGS T
44. ent rolling while parked Place support blocks underneath the trailers bumper to prevent tipping while parked Use the trailer s swivel jack to adjust the trailer height to a level position while parked TOWING SAFETY Check with your local county or state safety towing regulations in addition to meeting O Department of Transportation DOT Safety Towing Regulations before towing your light tower order to reduce the possibility of an accident while transporting the light tower on public roads ALWAYS make sure the trailer that supports the light tower and the towing vehicle are mechanically sound and in good operating condition ALWAYS shutdown engine before transporting Make sure the hitch and coupling of the towing vehicle are rated equal to or greater than the trailer gross vehicle weight rating ALWAYS inspect the hitch and coupling for wear NEVER tow a trailer with defective hitches couplings chains etc Check the tire air pressure on both towing vehicle and trailer Trailer tires should be inflated to 50 psi cold Also check the tire tread wear on both vehicles ALWAYS make sure the trailer is equipped with a safety chain ALWAYS properly attach trailer s safety chains to towing vehicle ALWAYS make sure the vehicle and trailer directional backup brake and trailer lights are connected and working properly DOT Requirements include the following
45. ere are no abnormal sounds Turn CB1 thru circuit breakers depending on what voltage is selected see Table 3 to the ON position Wait a few minutes and determine which lamp is not igniting If one of the lamps is OFF disconnect its power cable and plug it into a receptacle that is known to be working DO NOT unplug a power cable from the T Bar while power is being supplied by the generator Always turn the circuit breaker OFF before unplugging a power cable If the lamp still does not ignite after plugging it into a working receptacle 120 VAC present then the lamp is defective and has to be replaced the lamp ignites after plugging it into a working receptacle continue with step 7 With the voltmeter set to the AC position connect the negative lead of the AC voltmeter to any neutral white wire on the junction terminal block This block connects all the neutral wires white in the system PAGE 44 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 1 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 PAGE 5 ELECTRONIC COMPONENTS LOCATOR WIRING DIAGRAM SHEET 1 OUTPUT TERMINAL PANEL REAR CONNECTIONS GROUND CONNECTION MUST BE USED AT ALL TIMES 0 BLUE WHITE GREEN TO SMART RELAY Q1 1 GR
46. es a brake cable connected to the tow vehicle on one end and to the emergency brake lever located on the hydraulic actuator on the other end An ineffective breakaway brake system can result in a runaway trailer leading to death or serious injury if the coupler or ball hitch fails Connect the breakaway cable to the tow vehicle and NOT to the hitch ball or support Before towing the trailer test the function of the breakaway brake system If the breakaway brake system is not working DO NOT tow the trailer Have it serviced or repaired NOTICE DO NOT tow the trailer with the breakaway brake system ON because the brakes will overheat which can result in permanent brake failure NOTICE Replace the breakaway brake battery if equipped at intervals specified by manufacturer NOTICE Overloading can damage the tongue jack DO NOT use the tongue jack to raise the tow vehicle more than one inch If the coupler cannot be secured to the hitch ball do not tow the trailer Call your dealer for assistance Lower the trailer so that its entire tongue weight is held by the hitch and continue retracting the jack to its fully retracted position Attaching Safety Chain Visually inspect the safety chains and hooks for wear or damage Replace worn or damaged safety chains and hooks before towing Attach the safety chains so that they Cross underneath the coupler See Figure TOW VEHICLE A oo
47. es or pulleys immediately PAGE 22 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 MAINTENANCE 4 There are two pulleys in the mast raise lower cable system They should be removed and replaced if worn or damaged Worn or damaged pulleys can cause premature cable failure 5 Reassemble the mast extension cable system by connecting the cable to the bottom of the upper mast and sliding the upper mast into the opening of the center mast Connect the second cable to the bottom of the center mast and slide the center mast into the opening of the lower mast observing proper lifting techniques 6 Route the upper mast cable through the center mast pulley and connect the free end of the cable to the lower mast ankle shackle Route the center mast cable through the lower mast pulley and connect the free end of the cable to the hand winch at the bottom of the lower mast 7 Raise extend retract and lower the mast several times to verify correct operation SERVICING THE MAST EXTENSION CABLE SYSTEM To replace the cable in the mast extension cable system use the following steps See Figure 13 CENTER LOWER LOWER MAST MAST MAST ROUTE TO PULLEY SHACKLE HAND WINCH UPPER MAST MAST MAST Figure 13 Mast Extension Cable System 1 Lower the mast to the horizontal resting position 2 Inspectthe cable clamps pulleys and other components for worn or damaged parts If either of the cables on the mast n
48. esting position 2 Inspect the cable clamps pulleys and other components for worn or damaged parts 3 Disconnect the cable from the ball socket pin and remove from the mast pulley and cable sheave Detach the cable from the hand winch as necessary 4 Replace the pulley and the cable as needed 5 Rethread the cable through the pulley and reattach the cable to the ball socket pin 6 Raise and lower the mast several times to verify correct operation GENERAL INSPECTION Prior to each use the light tower should be cleaned and inspected Check for loose missing or damaged nuts bolts or other fasteners GENERATOR ENGINE MAINTENANCE Refer to the accompanying DCA25SSIUS Operator and Parts Manual Part Number 49810 for information on how to maintain the generator and engine CHECK CABLE WEAR The wire rope cable that raises and extends the mast is a very important part of the light tower There is one cable hand winch system located on the tongue of the trailer that raises and extends the light tower mast There is a second cable hand winch system located on the mast that serves to raise and lower the two extendable sections of the mast DANGER Wire rope cable will fail if it is worn frayed misused crushed kinked or damaged in any way Always check the cables and pulleys for any abnormalities before use Do not use it if there is even the slightest cause for concern and replace any damaged cabl
49. etermine the combined weight of luggage and cargo being loaded on the vehicle That weight may not safely exceed the available cargo and luggage capacity calculated in Step 4 If your vehicle will be towing a trailer load from your trailer will be transferred to your vehicle Consult the tow vehicle s manual to determine how this weight transfer reduces the available cargo and luggage capacity of your vehicle Studies of tire safety show that maintaining proper tire pressure observing tire and vehicle load limits not carrying more weight in your vehicle than your tires or vehicle can safely handle avoiding road hazards and inspecting tires for cuts slashes and other irregularities are the most important things you can do to avoid tire failure such as tread separation or blowout and flat tires These actions along with other care and maintenance activities can also Improve vehicle handling Help protect you and others from avoidable breakdowns and accidents Improve fuel economy Bi Increase the tire life There is a vehicle placard Figure 1 located in the same location as the certification label described above This placard provides tire and loading information In addition this placard will show a statement regarding maximum cargo capacity The weight of cargo should never exceed XXX kg Or XXX Ibs TIRE SIZE COLD TIRE PRESSURE em sore Figure 1 Trailer Tire Placard
50. ghting coverage of 5 to 7 acres The lamps are controlled by individual circuit breakers for versatility ENGINE The MLT25 Series Light Tower is powered by a diesel engine that is equipped with automatic shutdowns for low oil pressure high coolant temperature and alternator charge failure MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 PAGE 13 COMPONENTS o o o T Figure 2 Major Components Control Panel Side 6 Mast Cradle Support When towing of the light tower is required place the tower mast into the cradle support Make sure cradle lock release pin has been inserted and mast is locked T Bar Allows the lamps to be mounted vertically or horizontally Lamps Six 1000 watt metal halide bulbs with a 110 000 lumens capacity each Light coverage is typically between 5 to 7 acres Cradle Lock Release Pin Locks mast in cradle support and releases mast when removed Rear Jackstands There are two jackstands located at the rear of the trailer Use these jackstands to level and support the light tower Chock Blocks Place these blocks not included as part of the light tower package under each trailer wheel to prevent rolling Outrigger Jacks Use these 2 outrigger jacks to level and support the light tower For more stability the outriggers can be dep
51. he trailer tongue Refer to the wiring diagram shown in the trailer wiring diagram section of this manual Before towing the trailer check for the following Running lights turn on tow vehicle headlights Brake Lights step on tow vehicle brake pedal Backup Lights place tow vehicle gear shift in reverse Turn Signals activate tow vehicle directional signal lever Improper electrical connection between the tow vehicle and the trailer will result in inoperable lights and electric brakes and can lead to collision Before each tow Check that the taillights brake lights and turn signals work Check that the electric brakes work by operating the brake controller inside the tow vehicle Uncoupling the Ball Hitch Follow these steps to uncouple ball hitch from tow vehicle Block trailer tires to prevent the trailer from rolling before jacking the trailer up Disconnect the electrical connector Disconnect the breakaway brake switch cable Promptly replace the pullpin in the switchbox Before extending jackstand make certain the ground surface below the jackstand foot will support the tongue load Rotate the jackstand handle or crank clockwise This will slowly extend the jack and transfer the weight of the trailer tongue to the jack PAGE 34 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 SAFETY GUIDELINES TRAILERS A defective pintle
52. hitch ball for wear corrosion and cracks Replace worn or damaged hitch ball A loose hitchball nut can result in uncoupling leading to death or serious injury Be sure the hitch ball is tightto the hitch before coupling the trailer Rock the ball to make sure it is tightened to the hitch and visually check that the hitch ball nut is solid against the lock washer and hitch frame Wipe the inside and outside of the coupler Clean and visually inspect it for cracks and deformations Feel the inside of the coupler for worn spots and pits Be sure the coupler is secured tightly to the tongue of the trailer All coupler fasteners must be visibly solid against the trailer frame The bottom surface of the coupler must be above the top of the hitch ball Use the tongue jackstand to support PAGE 32 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 SAFETY GUIDELINES TRAILERS Breakaway Brake System If the coupler or hitch fails a properly connected and working breakaway brake system Figure F will apply the hydraulic brakes on the trailer The safety chains will keep the tow vehicle attached and as the brakes are applied at the trailers axles the trailer tow vehicle combination will come to a controlled stop Breakaway Lever Connect Cable to Tow Vehicle Hydraulic Actuator Figure F Breakaway Brake System Breakaway Cable Surge Brake System The breakaway brake system includ
53. hitch not properly fastened can result in uncoupling leading to death or serious injury Be sure the pintle hook is securly tighten to the tow vehicle before coupling the trailer Coupling Trailer to Tow Vehicle Pintle Coupler Slowly back up the tow vehicle so that the pintle hitch hook is near or aligned under the pintle eye ring coupler Using the jackstand at the front of trailer tongue turn the jackstand crank handle to raise the trailer If the pintle eye coupler does not line up with the pintle hitch hook adjust the position of the tow vehicle OPEN the pintle hook locking mechanism Figure Place the hook inside the eye coupler CLOSE the pintle hook mechanism TRAILER PINTLE TONDU 8 SAFETY CHAIN ff MASTER LINK PINTLE RING EYE IMPORTANT CROSS BOTH SAFETY CHAINS Figure H Attaching Safety Chain Pintle Hitch SAFETY CHAIN Insert a pin or lock through the hole in the locking mechanism Be sure the pintle hook is inserted completely through the eye ring and the locking mechanism is engaged A properly engaged locking mechanism will allow the coupler to raise the rear of the tow vehicle Using the trailer jack test to see that you can raise the rear of the tow vehicle by1 inch after the coupler is locked to the hitch Lower the trailer so that its entire tongue weight is held by the hitch Raise the jackstand to a height where it will not interfere
54. igure C connects to a ball that is located on or under the rear bumper of tow vehicle This system of coupling a trailer to a tow vehicle is sometimes referred to as bumper pull A ball hitch trailer may be fitted with a tongue jack that can raise and lower the coupler The tongue jack is mounted to the A frame front or tongue part of the trailer By rotating the jack handle clockwise the jack will extend and raise the tongue of the trailer Before each tow coat the ball with a thin layer of automotive bearing grease to reduce wear and ensure proper operation Check the locking device that secures the coupler to the ball for proper operation If you see or feel evidence of wear such as flat spots deformations pitting or corrosion on the ball or coupler immediately have your dealer inspect them to determine the proper action to prevent possible failure of the ball and coupler system All bent or broken coupler parts must be replaced before towing the trailer The coupler handle lever must be able to rotate freely and automatically snap into the latched position Oil the pivot points sliding surfaces and spring ends with SAE 30W motor oil Keep the ball socket and latch mechanism clean Dirt or contamination can prevent proper operation of the latching mechanism The load rating of the coupler and the necessary ball size are listed on the trailer tongue You must provide a hitch and ball for your tow vehicle where the lo
55. in with a wobble the bearings must be serviced or replaced Check inflation pressure weekly during use to insure the maximum tire life and tread wear Most trailer axles are built with sealed bearings that are not serviceable Sealed bearings must be replaced as complete units PAGE 40 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 SAFETY GUIDELINES TRAILERS Table C Tire Torque Requirements Replace any broken or burned out lamps as necessary Check the wire harness for cuts fraying or other damage Wheel size ee eee eee If it needs replacing contact your dealer 20 25 35 40 50 65 Improper operating taillights stoplights and turn signals can cause collisions Check all lights before each tow Lights and Signals Before each tow check the trailer taillights stoplights turn signals and any clearance lights for proper operation CONNECT TO cHassis GROUND RIGHT TAIL LIGHT GREEN BROWN YELLOW BROWN LICENSE TAIL LIGHT FLAT 4 PIN MOLDED MATING CONNECTOR FLAT 4 PIN MOLDED CONNECTOR 1 1 1 1 LEFT TAIL LIGHT 1 1 1 1 CHASSIS GROUND ELECTRIC BRAKE WHITE COMMON GROUND BLUE ELECTRIC BRAKE GREEN RIGHT STOP 8 TURN WHITE ey BLUE RIGHT GREEN TAILLIGHT faa BROWN RIGHT TURN SIGNAL HAZZARD GREEN 7 PIN ROUND 7 PIN ROUND 1
56. loyed Figure 2 and Figure 3 show the location of the controls and components for the MLT25 Series light tower The function of each control is described below Mast Rotation Locking Knob Unscrew this knob to release mast for rotation Tighten this knob to lock mast after it is set to the desired position Mast Extension Winch Use this winch to extend the mast to the desired height Maximum height is approximately 31 5 feet 9 6 meters Mast Rotation Handles Grip these handles to rotate mast to desired position Lifting Bale Light tower can be lifted using this lifting bale The lifting bale is balanced for a fully configured light tower Removal of any components will unbalance the lifting bale Forklift Pockets Light tower can be lifted using these forklift pockets Insert the forks of the forklift as far possible into the pockets PAGE 14 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 1 COMPONENTS FRONT VIEW a anm a a REAR VIEW Figure 3 Major Components Front Rear Fuse Block Assembly Contains the fuses that protect the lamp circuit breakers
57. nd unauthorized personnel To prevent the light tower from overturning NEVER use in winds that exceed 65 mph 105 kph LAMP SAFETY NEVER attempt to replace lamp with the power on Always shut down the engine and turn off circuit breakers when changing the lamp ALWAYS allow a sufficient amount of time for the lamp to cool before touching or changing The possibility exists of severe burns NEVER useforce when installing the lamp Excessive force could cause the lamp to break causing bodily harm NOTICE NEVER leave any grease or oil residue on lamp surface when replacing or removing lamp This can create hot spots reducing the service life of the lamp ALWAYS make sure lamp surface is clean and dry ALWAYS replace with MQ recommended type lamp ALWAYS have a trained technician install and remove a floodlight or replace any damaged fixture wiring LIGHT TOWER SAFETY DANGER NEVER operate the equipment in an explosive atmosphere or near combustible materials An explosion or fire could result causing severe bodily harm or even death NEVER disconnect any emergency or safety devices These devices are intended for operator safety Disconnection of these devices can cause severe injury bodily harm or even death Disconnection of any of these devices will void all warranties NEVER lubricate components or attempt service on a running machine ALWAYS ensure
58. osition the locking mechanism securely holds the coupler to the hitch ball Insert a pin or lock through the hole in the locking mechanism Be sure the coupler is all the way on the hitch ball and the locking mechanism is engaged A properly engaged locking mechanism will allow the coupler to raise the rear of the tow vehicle Using the trailer jackstand verify that you can raise the rear of the tow vehicle by 1 inch after the coupler is locked to the hitch Lower the trailer so that its entire tongue weight is held by the hitch Raise the jackstand to a height where it will not interfere with the road or is worn the trailer can come loose from the tow vehicle and may cause death or serious injury THE TOW VEHICLE HITCH AND BALL MUST HAVE A RATED TOWING CAPACITY EQUAL TO OR GREATER THAN THE TRAILER Gross Vehicle Weight Rating GVWR IT IS ESSENTIAL THAT THE HITCH BALL BE OF THE SAME SIZE AS THE COUPLER The ball size and load rating capacity are marked on the ball Hitch capacity is marked on the hitch Coupler to hitch mismatch can result in uncoupling leading to death or serious injury Be sure the LOAD RATING of the hitch ball is equal or greater than the load rating of the coupler Be sure the SIZE of the hitch ball matches the size of the ball coupler worn cracked or corroded hitch ball can fail while towing and may result in death or serious injury Before coupling trailer inspect the
59. overhead power lines or other obstructions could result in equipment damage electrical shock electrocution and even death Similar to boom equipment light tower may become energized with high voltage DO NOT operate the light tower within a radial distance of 17 feet from high voltage power lines If light tower becomes energized with high voltage contact with the equipment could result in electrocution PAGE 10 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 SPECIFICATIONS Table 1 MLT25 Series Specifications Light Tower Specifications POE With Fuel 4 450 Ib 2 018 kg Without Fuel 3 740 1 bou Six 1 000 Watt Metal Halide 660 000 Light Color Bright White Trailer Specifications Refer to Accompanying DCA25SSIUS Operation and Parts Generator Engine specincauens Manual Part No 49810 for generator engine specifications MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 PAGE 11 DIMENSIONS Y F AE DEPLOYED POSITION C STOWED POSITION D r 8 gt L E B Figure 1 Dimensions Table 2 Dimensions Length Mast Stowed Position 170 in
60. p Replace lamp PAGE 42 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 TROUBLESHOOTING Table 5 Lamp Troubleshooting continued Possible Cause 2 Lamp starts slowly ARC does not strike when switch is first turned on hea breaker trips on Short Circuit or Ground Check wiring against diagram Check for shorts or ground amp start up Normal Lamp Dirty Lamp or Fixture Clean lamp and fixture Interchange ballast plugs in generator enclosure If lamp returns to normal light output replace ballast Check for swollen capacitor charred wiring core and coil or other signs of excessive heat Lamp may glow for extended period of time Replace after 2 Defective Lamp checking voltage and ballast j 2 Lamp light output low Defective Ballast Check voltage at ballast input Voltage should be within 10 Wrong Voltage of nameplate rating Check wiring connections for voltage loss Check socket contact point Improper Ballast Check ballast nameplate against lamp data Lamp output and brightness decreases and color changes Normal Lamp slightly as lamps age Spot replacement with new lamps Depreciation may cause noticeable differences in lamp colors Group replacement minimizes color differences LARD OIS MISTEDE Dirty Fixture Dirty fixtures will cause lamps to appear different in color Clean fixture Wrong Lamp Check data on lamps which appear different in color Replace
61. r filter for dirt and dust If air filter is dirty replace air filter with a new one as required 4 Check all fastening nuts and bolts for tightness The engine s exhaust contains harmful emissions ALWAYS ventilate the exhaust when operating inside tunnels excavations or buildings Direct exhaust away from nearby personnel Before starting the engine make sure of the following E The electrical load is disconnected and the main circuit breaker and all lamp circuit breakers are switched to the OFF position NEVER start the engine with any circuit breakers in the ON position Light tower is placed on secure level ground with chock blocks underneath each wheel to prevent the light tower from rolling Outriggers have been fully extended to prevent the trailer from tipping Light tower trailer support stands have been positioned properly and the trailer is level Lamps have been adjusted to desired position Chocked blocks have been positioned under each wheel to prevent trailer from rolling Light tower trailer frame has been grounded correctly Lamps do not interfere with any overhead obstructions PAGE 16 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 INSPECTION b Locate the key slot A on each female connector as shown in Figure 5 MALE CONNECTOR FEMALE CONNECTOR SEB KEY SLOT A KEY TAB B Figure 5 Female and Male Connector c Onthe
62. railer Failure to read understand and follow the safety guidelines could result in injury to yourself and others Loss of control ofthe trailer or tow vehicle can result in death or serious injury COMMON CAUSES FOR LOSS OF TRAILER Driving too fast for the conditions maximum speed when towing a trailer is 55 mph Overloading the trailer or loading the trailer unevenly Trailer improperly coupled to the hitch No braking on trailer Not maintaining proper tire pressure Not keeping lug nuts tight Not properly maintaining the trailer structure Ensure machine is towed level to tow vehicle TRAILER TOWING GUIDELINES Recheck the load tiedowns to make sure the load will not shift during towing Before towing check coupling safety chain safety brake tires wheels and lights Check the lug nuts or bolts for tightness Check coupler tightness after towing 50 miles Use your mirrors to verify that you have room to change lanes or pull into traffic Use your turn signals well in advance Allow plenty of stopping space for your trailer and tow vehicle Allow plenty of stopping space for your trailer and tow vehicle DO NOT drive so fast that the trailer begins to sway due to speed Allow plenty of room for passing A rule of thumb is that the passing distance with a trailer is 4 times the passing distance without the trailer MLT25 SERIES LIGHT TOWE
63. rd stopping These brakes require manual adjustment The following steps apply to adjust most manually adjustable brakes 1 Jack up the trailer and secure it on adequate capacity jackstands 2 Be sure the wheel and brake drum rotate freely 3 Remove the adjusting hole cover from the adjusting slot on the bottom of the brake backing plate 4 With a screwdriver or standard adjusting tool rotate the starwheel of the adjuster assembly to expand the brake shoes Adjust the brake shoes out until the pressure of the linings against the drum makes the wheel very difficult to turn Note Your trailer maybe equipped with drop spindle axles See axle manual for your axle type You will need a modified adjusting tool for adjusting the brakes in these axles With drop spindle axles a modified adjusting tool with about an 80 degree angle should be used 5 Rotate the starwheel in the opposite direction until the wheel turns freely with a slight drag PAGE 24 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 MAINTENANCE TRAILERS ADJUSTABLE CHANNEL 5 8 X 11 X 5 BOLT 5 8 FLAT 2 or 2 5 16 BALL WASHER COUPLER Figure 16 Adjustable Channel Wheel Bearings Wheel bearings Figure 17 must be inspected and lubricated once a year or 12 000 miles to insure safe operation of your trailer If trailer wheel bearings are immersed in water they must be replaced DANGER If trailer wheels
64. readwear Number This number indicates the tire s wear rate The higher the treadwear number is the longer it should take for the tread to wear down For example a tire graded 400 should last twice as long as a tire graded 200 Traction Letter This letter indicates a tire s ability to stop on wet pavement A higher graded tire should allow you to stop your car on wet roads in a shorter distance than a tire with a lower grade Traction is graded from highest to lowest as and Temperature Letter This letter indicates a tire s resistance to heat The temperature grade is for a tire that is inflated properly and not overloaded Excessive speed underinflation or excessive loading either separately or in combination can cause heat build up and possible tire failure From highest to lowest a tire s resistance to heat is graded as B or C Refer to Figure K for additional tire information for light trucks Maximum load amp inflaton Load Range when used as a dual Light Severe snow Q conditons Maximum losd amp inflabon when used as a single Figure K UTQGS Tire Information Load inflation limite Tires for light trucks have other markings besides those found on the sidewalls of passenger tires LT The LT indicates the tire is for light trucks or trailers ST An ST is an indication the tire is for trailer use only Max Load Dual kg Ibs at kPa psi Cold
65. s clockwise to lower it and level the light tower 4 Check behind the light tower and make sure all personnel and objects are clear of the mast See Figure 6 for location of components Deploying the Mast to Vertical Position 1 Make sure both outriggers are extended To extend the outriggers pull the locking pin on the outrigger and hold while sliding out the outrigger assembly 1 To release the mast from the mast cradle support pull the retaining pin out of the cradle lock release pin Pull the cradle lock release pin This will unlock the mast from the horizontal position Outriggers and Support Stands Refer to Figure 7 for the location of components 2 Remove the mast lock release pin before raising tower to the vertical position 3 To place the mast in the vertical position turn the vertical mast winch hand lever clockwise until the mast is pointing upwards at 90 degrees 4 Once the mast is in the vertical position insert the mast lock release pin to prevent the mast from falling PAGE 18 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 OPERATION MAST CRADLE SUPPORT fa CRADLE LOCK RELEASE MAST ROTATION HANDLE 2 MAST LOCK HANDLE MAST ROTATION LOCKING KNOB Figure 7 Raising the Mast MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 PAGE
66. s in the tire which include steel nylon polyester and others Maximum Load Rating This number indicates the maximum load in kilograms and pounds that can be carried by the tire Maximum Permissible Inflation Pressure This number is the greatest amount of air pressure that should ever be put in the tire under normal driving conditions Use the information contained in this section to make tire safety a regular part of your vehicle maintenance routine Recognize that the time you spend is minimal compared with the inconvenience and safety consequences of a flat tire or other tire failure TIRE FUNDAMENTALS Federal law requires tire manufacturers to place standardized information on the sidewall of all tires Figure J This information identifies and describes the fundamental characteristics of the tire and also provides a tire identification number for safety standard certification and in case of a recall Rim diameter code Load index 8 speed symbol 9 5 DOT tire z identification number Ratio of height to R width aspect ratio Nominal width of tire in millimeters Passenger car tire Severe snow conditions Tire ply composition and materials used Max permissable inflation pressure Treadwear traction and temperature grades Max load rating Figure J Standard Tire Sidewall Information The indicates the tire is for passenger vehicles Next number This three digi
67. sult in loss of control and may lead to death or serious injury Use of a tow vehicle with a towing capacity less than the load rating of the trailer can result in loss of control and may lead to death or serious injury Be sure your hitch and tow vehicle are rated for the Gross Vehicle Weight Rating of your trailer increased stopping distance and increased turning radius which means you must make wider turns to keep from hitting curbs vehicles and anything else that is on the inside corner In addition you will need a longer distance to pass due to slower acceleration and increased length Be alert for slippery conditions You are more likely to be affected by slippery road surfaces when driving a tow vehicle with a trailer than driving a tow vehicle without a trailer Check rearview mirrors frequently to observe the trailer and traffic NEVER drive faster than what is safe Driving too fast for severe road conditions can result in loss of control and cause death or serious injury Decrease your speed as road weather and lighting conditions deteriorate Always check for local trailer tow speed limits in your area Do not transport people on the trailer The transport of people puts their lives at risk and may be illegal COUPLING TO THE TOW VEHICLE Follow all of the safety precautions and instructions in this manual to ensure safety of persons equipment and satisfactory life of the trailer
68. suspension springs and associated components Figure 18 should be visually inspected every 6 000 miles for signs of excessive wear elongation of bolt holes and loosening of fasteners Replace all damaged parts suspension immediately SHACKLE SUPPORT BRACKET IS WELDED TO FRAME SHACKLE NUTS AXLE HANGER SUPPORT BRACKET IS WELDED TO FRAME LEAF SUSPENSION FRONT U BOLT HANGER BOLT LOCKING TIE PLATE NUT Figure 18 Leaf Suspension Components DANGER Worn or broken suspension parts can cause loss of control damage to equipment and severe bodily injury even death Check suspension regularly After removing the dust cap cotter pin spindle nut and spindle washer remove the hub to inspect the bearings for wear and damage Replace bearings that have flat spots on rollers broken roller cages rust or pitting Always replace bearings and cups in sets The inner and outer bearings are to be replaced at the same time Replace seals that have nicks tears or wear Lubricate the bearings with a high quality EP 2 automotive wheel bearing grease WHEEL HUB ADJUSTMENT Every time the wheel hub is removed and the bearings are reassembled follow the steps below to check the wheel bearings for free running and adjust Turn the hub slowly by hand while tightening the spindle nut until you can no longer turn the hub by hand Loosen the spindle nut just until you are able to turn it
69. t Failure to read and understand the safety messages and operating instructions could result in injury to yourself and others SAFETY MESSAGES The four safety messages shown below will inform you about potential hazards that could injure you or others The safety messages specifically address the level of exposure to the operator and are preceded by one of four words DANGER WARNING CAUTION or NOTICE SAFETY SYMBOLS DANGER Indicates a hazardous situation which if not avoided WILL result in DEATH or SERIOUS INJURY Indicates a hazardous situation which if not avoided COULD result in DEATH or SERIOUS INJURY Indicates a hazardous situation which if not avoided COULD result in MINOR or MODERATE INJURY NOTICE Addresses practices not related to personal injury MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 PAGE 5 SAFETY INFORMATION NOTICE This equipment should only be operated by trained qualified personnel 18 years of age and older Whenever necessary replace nameplate operation and safety decals when they become difficult read Manufacturer does not assume responsibility for any accident due to equipment modifications Unauthorized equipment modification will void all warranties NEVER use accessories or attachments that are not recommended by Multiquip for this equipment Damage to the equipment and or injury to user may result ALWAYS know
70. t number gives the width in millimeters of the tire from sidewall edge to sidewall edge In general the larger the number the wider the tire Next number This two digit number known as the aspect ratio gives the tire s ratio of height to width Numbers of 70 or lower indicate a short sidewall for improved steering response and better overall handling on dry pavement The stands for radial Radial ply construction of tires has been the industry standard for the past 20 years Next number This two digit number is the wheel or rim diameter in inches If you change your wheel size you will have to purchase new tires to match the new wheel diameter Next number This two or three digit number is the tire s load index It is a measurement of how much weight each tire can support You may find this information in your owners manual If not contact a local tire dealer Note You may not find this information on all tires because it is not required by law PAGE 38 MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 SAFETY GUIDELINES TRAILERS Load Range This information identifies the tire s load carrying capabilities and its inflation limits Tire Safety Tips Slow down if you have to go over a pothole or other object in the road DO NOT run over curbs or other foreign objects in the roadway and try not to strike the curb when parking Check tire inflation pressure we
71. te slack that will activate the system if the coupler connection comes loose JACKSTAND device on the trailer that is used to raise and lower the coupler The jack is sometimes called the landing gear or the tongue jack COUPLER TYPES Two types of coupler used wit the trailer are discussed below Ball Hitch Coupler Pintel Eye Coupler MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 PAGE 31 SAFETY GUIDELINES TRAILERS the trailer tongue Wood or concrete blocks may also be used Coupling the Trailer to the Tow Vehicle Ball Coupler Lubricate the hitch ball and the inside of the coupler with a thin layer of automotive bearing grease Slowly back up the tow vehicle so that the hitch ball is near or aligned under the coupler Using the jackstand at the front of trailer tongue turn the jackstand crank handle to raise the trailer If the ball coupler does not line up with the hitch ball adjust the position of the tow vehicle Open the coupler locking mechanism Ball couplers have a locking mechanism with an internal moving piece and an outside handle In the open position the coupler is able to drop fully onto the hitch ball Lower the trailer Figure D until the coupler fully engages the hitch ball 2 INCH TRAILER COUPLER Tow VEHICLE Figure D Ball Hitch Coupling Mechanism Engage the coupler locking mechanism In the engaged p
72. to stop when towing a trailer You will need to spend time adjusting to the different feel and maneuverability of the tow vehicle with a loaded trailer Because of the significant differences in all aspects of maneuverability when towing a trailer the hazards and risks of injury are also much greater than when driving without a trailer You are responsible for keeping your vehicle and trailer in control and for all the damage that is caused if you lose control of your vehicle and trailer As you did when learning to drive an automobile find an open area with little or no traffic for your first practice trailering Of course before you start towing the trailer you must follow all of the instructions for inspection testing loading and coupling Also before you start towing adjust the mirrors so you can see the trailer as well as the area to the rear of it MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 PAGE 29 SAFETY GUIDELINES TRAILERS To determine the empty or net weight of your trailer weigh it on an axle scale To find the weight of the trailer using an axle scale you must know the axle weights of your tow vehicle without the trailer coupled Some of the trailer weight will be transferred from the trailer to the tow vehicle axles and an axle scale weighs all axles including the tow vehicle axles TOW VEHICLE The towing hitch attached to your tow vehicle must have a Capacity equ
73. upler to be above the top of the pintle hitch hook Use the tongue jackstand to support the trailer tongue Wood or concrete blocks may also be used MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 PAGE 35 SAFETY GUIDELINES TRAILERS Lug nuts are also prone to loosen after first being assembled When driving a new trailer or after wheels have been remounted check to make sure they are tight after the first 10 25 and 50 miles of driving and before each tow thereafter Failure to perform this check can result in a wheel parting from the trailer and a crash leading to death or serious injury Lug nuts are prone to loosen after initial installation which can lead to death or serious injury Check lug nuts for tightness on a new trailer or when wheel s have been remounted after the first 10 25 and 50 miles of driving Improper lug nut torque can cause a wheel parting from the trailer leading to death or serious injury Be sure lug nuts are tight before each tow Improper tire pressure can result in a blowout and loss of control which can lead to death or serious injury Be sure tires are inflated to pressure indicated on side wall before towing trailer Determining Load Limit of Trailer Determining the load limits of a trailer includes more than understanding the load limits of the tires alone On all trailers there is a Federal certification VIN label that is located on the forward h
74. voltage 120 VAC is being supplied to the ballast Then it can be assumed that the ballast for that lamp is defective Replace ballast 10 Ballast Removal Remove the power cable from the generator and make sure that no voltage is being supplied to the ballast compartment Remove the four screws securing the ballast cover and remove cover Make sure to discharge the ballast capacitor Remove the defective ballast taking care to guard against electrical shock when coming in contact with the ballast and capacitor The capacitor is known to store an electrical charge that when discharged could result in a harmful shock Make sure to discharge capacitor 1 LAMP TROUBLESHOOTING GUIDE Use the following procedure and wiring diagrams on the next pages to determine which of the four lamps is not functioning Connections Make sure that lamp 1 power cable is plugged into the J1 connector on the T Bar assembly Make sure that lamp 2 power cable is plugged into the J2 connector on the T Bar assembly Make sure that lamp 3 power cable is plugged into the J3 connector on the T Bar assembly Make sure that lamp 4 power cable is plugged into the J4 connector on the T Bar assembly Make sure that lamp 5 power cable is plugged into the J5 connector on the T Bar assembly Make sure that lamp 6 power cable is plugged into the J6 connector on the T Bar assembly 1 Starting Start the generator and verify that th
75. with correct color lamp Over Voltage from Power Check voltage at ballast Check for current or voltage surges ARC tube discolored or Supply Check for shorted capacitors and replace if defective swollen Lamp operated on ballast designed for higher wattage lamp 2 Improper Palast Check ballast nameplate against lamp data Check for outer bulb cracks If air enters outer bulb arc tube may continue to burn for 100 hours before failure Check for bulb cracks where glass meets the base due to tightening Lamp Damaged Lamp too firmly in socket or scoring of glass where socket inadvertently touches the lamp bulb Look for broken arc tube Short lamp life or loose metal parts Replace lamp Bulb leads will cause oxidation of metal parts Ballast nameplate data should agree with lamp line voltage Improper Ballast and lamp use If improper ballast is used the lamp life will be shortened A mismatch may also cause the ballast to fail MLT25 SERIES LIGHT TOWER OPERATION MANUAL REV 0 11 28 12 PAGE 43 TROUBLESHOOTING 8 Connect the positive lead of the voltmeter to the output side of the circuit breaker where the lamp was originally OFF and observe that 120 VAC is present Make sure circuit breaker is ON If no output voltage is present the circuit breaker is defective and needs to be replaced If the correct output voltage is present then it can be assumed that the generator is working correctly and the correct

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