Multi Tech Equipment Indoor Furnishings MLT20DCA User Manual

OperatiOn Manual  
MODelS  
Mlt20DCa  
Mlt20DCa6  
DeDiCateD light tOwer  
Revision #0 (01/18/13)  
To find the latest revision of this  
publication, visit our website at:  
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.  
pn 49838  
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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-  
Administrator  
NHTSA  
1200 New Jersey Avenue S.E.  
Washington, DC 20590  
You can also obtain information about motor vehicle safety from  
MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13) — page 3  
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table Of COntentS  
Mlt20 Series light tower  
Proposition 65 Warning ........................................... 2  
Reporting Safety Defects......................................... 3  
Table Of Contents.................................................... 4  
Safety Information .............................................. 5-10  
Specifications ........................................................ 11  
Dimensions............................................................ 12  
General Information............................................... 13  
Components ..................................................... 14-15  
Inspection ......................................................... 16-17  
Operation.......................................................... 18-21  
Maintenance..................................................... 22-23  
Maintenance — Trailers.................................... 24-26  
Safety Guidelines — Trailers ............................ 27-41  
Troubleshooting ................................................ 42-44  
Electronic Componet Locator (MLT20DCA) .......... 46  
Electronic Componet Locator (MLT20DCA6) ........ 47  
Wiring Diagram (MLT20DCA)........................... 48-49  
Wiring Diagram (MLT20DCA6)......................... 50-51  
NOTICE  
Specifications are subject to change without notice.  
page 4 — MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13)  
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Safety infOrMatiOn  
Do not operate or service the equipment before reading the  
entire manual. Safety precautions should be followed at all  
times when operating this equipment. Failure to read and  
understand the safety messages and operating instructions  
could result in injury to yourself and others.  
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.  
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.  
WaRnIng  
Indicates a hazardous situation which, if not avoided,  
COuLD result in DeaTH or seRIOus InJuRY.  
CauTIOn  
Indicates a hazardous situation which, if not avoided,  
COuLD result in MInOR or MODeRaTe InJuRY.  
NOTICE  
Addresses practices not related to personal injury.  
MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13) — page 5  
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Safety infOrMatiOn  
geneRaL saFeTY  
NOTICE  
CauTIOn  
This equipment should only be operated by trained and  
qualified personnel 18 years of age and older.  
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.  
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.  
neveR operate this equipment when not  
feeling well due to fatigue, illness or when  
under medication.  
aLWaYs know the location of the nearest  
fire extinguisher.  
neveR operate this equipment under the influence of  
drugs or alcohol.  
aLWaYs know the location of the nearest  
first aid kit.  
aLWaYs check the equipment for loosened threads or  
bolts before starting.  
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.  
DO nOT use the equipment for any purpose other than  
its intended purposes or applications.  
page 6 — MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13)  
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Safety infOrMatiOn  
LIgHT TOWeR saFeTY  
NOTICE  
DangeR  
aLWaYs keep the immediate area surrounding the light  
tower clean, neat, and free of debris.  
neveRoperatetheequipmentinanexplosive  
atmosphereornearcombustiblematerials.An  
explosion or fire could result causing severe  
bodily harm or even death.  
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 and unauthorized personnel.  
WaRnIng  
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.  
To prevent the light tower from overturning, neveR use  
in winds that exceed 65 mph (105 kph).  
LaMp saFeTY  
CauTIOn  
WaRnIng  
neveR lubricate components or attempt service on a  
running machine.  
neveR attempt to replace lamp with the power on.  
Always shut down the engine and turn off circuit breakers  
when changing the lamp.  
aLWaYs ensure 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 allow a sufficient amount of time for the lamp to  
cool before touching or changing. The possibility exists of  
severe burns.  
ALWAYS make sure trailer is leveled with all outriggers  
extended before raising tower. Outriggers must remain  
extended while tower is up.  
CauTIOn  
neveRuseforcewheninstallingthelamp.Excessiveforce  
could cause the lamp to break, causing bodily harm.  
ALWAYS keep area behind trailer clear of people while  
raising and lowering mast.  
NOTICE  
neveR remove safety pin or pull mast locking pin while  
tower is in a raised position!  
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.  
CHeCK the mast and winch cables for wear. If any  
problem occurs when lowering or raising the tower, STOP  
immediately! Contact a trained technician for assistance.  
aLWaYs make sure lamp surface is clean and dry.  
aLWaYs replace with MQ recommended type lamp.  
neveR pivot or retract mast while unit is operating.  
aLWaYs have a trained technician install and remove  
a floodlight, or replace any damaged fixture wiring.  
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 lower the light tower when not in use, or if high  
winds or electrical storms are expected.  
MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13) — page 7  
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Safety infOrMatiOn  
Avoid sudden stops and starts.This can cause skidding,  
or jack-knifing. Smooth, gradual starts and stops will  
improve towing.  
TOWIng saFeTY  
CauTIOn  
Check with your local county or state safety  
towing regulations, in addition to meeting  
Department of Transportation (DOT)  
SafetyTowing Regulations, before towing  
your light tower.  
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.  
In 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.  
Place chock blocks underneath wheel to prevent rolling  
while parked.  
Place support blocks underneath the trailer’s bumper  
to prevent tipping while parked.  
aLWaYs shutdown engine before transporting.  
Use the trailer’s swivel jack to adjust the trailer height to  
a level position while parked.  
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:  
• Connect and test electric brake operation.  
• Secure portable power cables in cable tray with tie  
wraps.  
The maximum speed for highway towing is55 MpHunless  
posted otherwise.Recommended off-road towing is not to  
exceed 15 MpH or less depending on type of terrain.  
page 8 — MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13)  
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Safety infOrMatiOn  
If lifting through pockets, make sure forks of forklift are  
inserted in pockets as far as possible before lifting.  
TRanspORTIng saFeTY  
CauTIOn  
Never allow any person or animal to stand underneath the  
equipment while lifting.  
Before lifting, make sure that light tower parts are not  
damaged and screws are not loosened or lost.  
DO nOT lift equipment to unnecessary heights.  
Loading and Tie-Down on Flatbed Truck  
NOTICE  
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.  
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.  
STOWED  
POSITION  
FRONT  
JACKSTAND  
RETRACTED  
TONGUE  
TRANSPORT  
TIE-DOWN  
POINT  
SIDE  
JACK  
STAND  
(2)  
REAR  
JACK  
STAND  
(2)  
aLWaYs Make sure rear mast lock is secure before  
lifting.  
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.  
Use adequate lifting cable (wire or rope) of sufficient  
strength.  
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.  
Use one point suspension hook and lift straight upwards.  
DO nOT secure the unit by running a strap or chain over  
the tongue of the light tower. This may cause severe  
damage to the unit.  
LIFTING BALE  
LIGHT TOWER  
FORKLIFT  
POCKETS  
(2)  
MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13) — page 9  
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Safety infOrMatiOn  
eLeCTRICaL saFeTY  
DangeR  
.
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 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 — MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13)  
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SpeCifiCatiOnS  
Table 1. MLT20 series specifications  
Light Tower specifications  
With Fuel - 4,450 lb. (2,018 kg.)  
Weight (with genset/trailer)  
Without Fuel - 3,740 lb. (1,696 kg.)  
Four 1,000-Watt Metal Halide  
Six 1,000-Watt Metal Halide  
660,000  
MLT20DCA  
MLT20DCA6  
Lamps  
Lumens  
Light Color  
Bright White  
Trailer specifications  
Trailer Model  
TRLR75XF  
Gross Vehicle Weight Rating (GVWR)  
Gross Axle Weight Rating (GAWR) (ea.)  
Tire Size  
7,000 lb (3,175 kg.)  
3,500 lb (1,587 kg)  
ST205/75D15 LR-C  
1,820 lb (825 kg)  
5-Lug on 4.5 in  
Tire Load Rating (ea.)  
Wheel Bolt Pattern  
Fuel Tank Capacity  
100 gal (378 L)  
Refer to Accompanying DCA20SPXU2 Operation and Parts  
Manual (Part No. 49840) for generator/engine specifications.  
generator/engine specifications  
MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13) — page 11  
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DiMenSiOnS  
DEPLOYED  
POSITION  
C
STOWED  
POSITION  
D
E
F
B
A
G
Figure 1. Dimensions  
Table 2. Dimensions  
Description  
Reference Letter  
Dimension  
A
B
C
D
E
F
Length (Mast Stowed Position)  
Length (Mast Deployed Position)  
Max. Height (Mast Deployed Position)  
Height (Mast Stowed Position)  
Ground Clearance (From Axle)  
Width (Tow Ready)  
170 in. (431 cm.)  
101 in. (256 cm.)  
31.5 ft. (9.6 m)  
74 in. (187 cm.)  
8 in. (20 cm.)  
51 in. (129 cm.)  
109 in. (276 cm.)  
G
Width (Outriggers Deployed)  
page 12 — MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13)  
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general infOrMatiOn  
sTaBILITY  
The Multiquip MLT20 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.  
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.  
MeTaL HaLIDe LaMps  
The MLT20 Series Light Tower is available with 6 metal  
halide, 1000-watt lamps (MLT20DCA6) or with 4 metal  
halide, 1000-watt lamps (MLT20DCA).These lamps provide  
maximum illumination with typical lighting coverage of 5  
to 7 acres. The lamps are controlled by individual circuit  
breakers for versatility.  
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  
engIne  
The trailer design of the MLT20 Series light tower  
withstands the rigors of the jobsite in addition to providing  
smooth highway towing.  
The MLT20 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.  
NOTICE  
TheillustrationsinthismanualshowmodelMLT20DCA6  
(with 6 lamps). However, information is also applicable  
to the MLT20DCA (with 4 lamps) unless stated  
otherwise.  
MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13) — page 13  
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COMpOnentS  
2
16  
3
9
8
4
1
6
5
5
7
17  
13  
19  
15  
10  
18  
12  
14  
11  
18  
Figure 2. Major Components (Control Panel Side)  
Figure 2 and Figure 3 show the location of the controls and  
components for the MLT20 Series light tower.The function  
of each control is described below.  
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.  
1. 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.  
7. T-Bar — Allows the lamps to be mounted vertically or  
horizontally.  
2. Mast extension Winch — Use this winch to extend  
the mast to the desired height. Maximum height is  
approximately 31.5 feet (9.6 meters).  
8. Lamps — Six (MLT20DCA6) or Four (MLT20DCA)  
1000-watt metal-halide bulbs with a 110,000 lumens  
capacity each.  
3. Mast Rotation Handles — Grip these handles to rotate  
mast to desired position.  
9. Cradle Lock/Release pin — Locks mast in cradle  
support and releases mast when removed.  
4. 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.  
10. Rear Jackstands There are two jackstands located  
at the rear of the trailer. Use these jackstands to level  
and support the light tower.  
11. Chock Blocks — Place these blocks (not included  
as part of the light tower package) under each trailer  
wheel to prevent rolling.  
5. Forklift pockets — Light tower can be lifted using  
these forklift pockets. Insert the forks of the forklift as  
far possible into the pockets.  
12. Outrigger Jacks — Use these 2 outrigger jacks to  
level and support the light tower.For more stability, the  
outriggers can be deployed.  
page 14 — MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13)  
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COMpOnentS  
22  
21  
21  
20  
23  
REAR VIEW  
FRONT VIEW  
Figure 3. Major Components (Front/Rear)  
13. Tongue Jackstand — Use this jackstand to support  
the tongue when attaching the light tower to a towing  
vehicle.  
19. Circuit Breakers Turn the lamps on and off.  
20. License Light This light illuminates the license plate.  
Whenever towing of the light tower is required, make  
sure this light is operational.  
14. safety Chain — Always attach safety chain to the  
towing vehicle.Never tow the light tower with the safety  
chain unattached.  
21. 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.  
15. 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.  
22. 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.  
16. vertical Mast Winch — Use this winch to raise the  
mast to the vertical position.  
23. 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.  
17. Mast Lock/Release pin — Pull this pin to start placing  
the tower mast in the vertical position. When tower  
mast has reached full vertical position, insert pin to  
keep mast from falling.  
18. 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.  
MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13) — page 15  
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inSpeCtiOn  
BeFORe sTaRTIng  
DangeR  
1. Read all safety instructions at the beginning of  
manual.  
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!  
2. Clean the light tower, removing dirt and dust, particularly  
the engine cooling air inlet and air cleaner.  
3. Check the air 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.  
WaRnIng  
Lamp 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.  
The engine's exhaust contains harmful  
emissions.aLWaYs ventilate the exhaust  
when operating inside tunnels, excavations  
or buildings. Direct exhaust away from  
nearby personnel.  
a. Locate the 6 (4 for the MLT20DCA) key-lock, 3-pin,  
female connectors on the T-bar. See Figure 4.  
Before starting the engine, make sure of the following:  
FRONT  
The electrical load is disconnected and the main circuit  
breaker and all lamp circuit breakers are switched to the  
OFF position.  
REAR  
LAMP 1  
CauTIOn  
LAMP 4  
neveR start the engine with any circuit breakers in  
the ON position.  
LAMP 2  
LAMP 5  
Light tower is placed on secure level ground with chock  
blocks underneath each wheel to prevent the light tower  
from rolling.  
LAMP 3  
LAMP 6  
Outriggers have been fully extended to prevent the trailer  
from tipping.  
T-BAR  
MAST RAISED  
J1  
J2  
J3  
J4  
J5  
J6  
Light tower trailer support stands have been positioned  
properly and the trailer is level.  
ORS  
FEMALE CONNECT  
Lamps have been adjusted to desired position.  
Chocked blocks have been positioned under each wheel  
to prevent trailer from rolling.  
LOCKING NUT  
OR)  
(MALE CONNECT  
Light tower trailer frame has been grounded correctly.  
Figure 4. T-Bar and Cable Connectors  
Lamps do not interfere with any overhead obstructions.  
page 16 — MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13)  
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inSpeCtiOn  
b. Locate the key slot A on each female connector  
as shown in Figure 5.  
TOR  
MALE CONNEC  
TOR  
FEMALE CONNEC  
T A  
KEY SLO  
B
KEY TAB  
Figure 5. Female and Male Connector  
c. On the 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.  
e. 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.  
MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13) — page 17  
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OperatiOn  
sTaRTIng THe engIne  
NOTICE  
Refer to the accompanying DCA20SPXU2 generator  
operation and parts manual (Part Number 49840) for  
information on how to start the engine.  
PULL PIN TO  
RELEASE  
OUTRIGGER  
MasT OpeRaTIOn  
DangeR  
PULL OUTRIGGER  
TO EXTEND  
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  
or death!  
OUTRIGGER  
ROTATE  
JACKSTAND  
TO PLACE  
IN SUPPORT  
POSITION  
JACKSTAND  
Figure 6. Deploying Outriggers  
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  
extended position.  
DangeR  
DO nOT stand behind  
the trailer while the  
mast is 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 jackstands 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.  
Outriggers and support stands  
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.  
Refer to Figure 7 for the location of components:  
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.  
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 — MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13)  
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OperatiOn  
MAST  
RT  
CRADLE SUPPO  
CRADLE  
LOCK/RELEASE  
LEVER  
TION  
ROTA  
MAST  
HANDLE (2)  
LOCK  
MAST  
HANDLE  
MAST  
TION  
ROTA  
LOCKING  
KNOB  
LOCK/RELEASE PIN  
MAST  
Figure 7. Raising the Mast  
MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13) — page 19  
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OperatiOn  
1. With the mast in the deployed position (vertical),  
unscrew the mast rotation locking knob to release the  
mast for rotation.  
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.  
2. Grip the mast rotation handles and rotate the mast until  
the lamps are facing the desired direction.  
Refer to Figure 7 for location of components.  
3. When the lamps are facing the desired direction,  
tighten the mast rotation lock knob to lock the mast  
in place.  
1. Turn the mast extension winch clockwise and observe  
that the mast begins to extend upwards.  
2. Continue turning the winch in the clockwise direction  
until the desired height has been reached.  
TuRnIng OnTHe LaMps  
Lamp circuit breakers (15 amps each) are located on the  
front of the light tower to turn the lamps on and off. See  
Table 3.  
3. Release the winch. This winch is of the self-locking  
type. The tension on the cable will keep the mast in  
place.  
Table 3. Lamp settings  
Lowering the Mast  
Circuit Breaker (On)  
Lamps (On)  
1. Turn the mast extension winch counterclockwise, and  
observe that the mast begins to lower.  
CB1  
CB2  
CB3  
CB4  
CB5  
CB6  
1
2
3
4
5
6
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.  
NOTICE  
Model MLT20DCA has only 4 lamps and 4 circuit  
breakers.  
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.  
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.  
CB1  
CB3  
CB5  
CB2  
CB4  
CB6  
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.  
Figure 8. Lamp Circuit Breakers  
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OperatiOn  
2. Adjust the Voltage Regulator Knob to 120VAC. Check  
the AC voltmeter for the correct reading. See Figure 9.  
4. When the lamps turn on, check the AC voltmeter  
reading and adjust the Voltage Regulator knob, if  
necessary, to correct the voltage.  
5. If any of the lamps do not turn on as they should, refer  
to the troubleshooting section of this manual.  
6. Close all cabinet doors after desired lights are on.  
INCREASE  
DECREASE  
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.  
AC Voltmeter  
Voltage Regulator  
Figure 9. Voltage Regulator Knob and AC  
Voltmeter  
3. Switch the appropriate circuit breakers to the ON  
position for the lamps (Figure 10) that you want to turn  
on as detailed in Table 3.  
FRONT  
REAR  
LAMP 1  
LAMP 4  
LAMP 2  
LAMP 5  
LAMP 3  
LAMP 6  
MAST RAISED  
Figure 10. Lamp Orientation (MLTDCA6)  
MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13) — page 21  
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MaintenanCe  
seRvICIng THe MasT RaIse/LOWeR CaBLe  
sYsTeM  
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.  
To replace any components in the mast raise/lower cable  
system, use the following steps (See Figure 11):  
geneRaTOR/engIne MaInTenanCe  
HAND WINCH  
Refer to the accompanying DCA20SPXU2 Operator and  
Parts Manual (Part Number 49840) 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.  
CABLE  
MAST  
PULLEY  
CABLE SHEAVE  
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 cables or pulleys  
immediately.  
Figure 11. Mast Raise/Lower Cable System  
1. Lower the mast to the horizontal resting position.  
2. Inspectthecableclamps,pulleys,andothercomponents  
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.  
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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.  
seRvICIng THe MasT exTensIOn CaBLe  
sYsTeM  
To replace the cable in the mast extension cable system,  
use the following steps (See Figure 12):  
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.  
LOWER  
MAST  
LOWER  
MAST  
CENTER  
MAST  
ROUTE TO  
HAND WINCH  
PULLEY  
SHACKLE  
PULLEY  
LOWER  
MAST  
CENTER  
MAST  
UPPER  
MAST  
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.  
Figure 12. Mast Extension Cable System  
1. Lower the mast to the horizontal resting position.  
2. Inspectthecableclamps,pulleys,andothercomponents  
for worn or damaged parts. If either of the cables on  
the mast needs to be replaced, they should both be  
replaced at the same time.  
7. Raise, extend, retract and lower the mast several times  
to verify correct operation.  
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.  
WaRnIng  
The mast sections are heavy and awkward to handle.  
Use proper lifting devices and procedures when  
servicing the mast and its components.  
MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13) — page 23  
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MaintenanCe — trailerS  
The following trailer maintenance guidelines are intended  
to assist the operator in preventive maintenance.  
6. Replace the adjusting-hole cover.  
7. Repeat the above procedure on all brakes.  
8. Lower the trailer to the ground.  
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.  
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.  
HYDRauLIC BRaKes  
Figure 13 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.  
If 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 hard 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.  
Figure 13. Hydraulic Brake Components  
3. Remove the adjusting-hole cover from the adjusting  
slot on the bottom of the brake backing plate.  
HYDRauLIC BRaKe aCTuaTOR  
The hydraulic brake actuator (Figure 14) is the mechanism  
that activates the trailer’s 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.  
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.  
HYDRAULIC  
BRAKE FLUID  
RESERVOIR  
5. Rotate the starwheel in the opposite direction until the  
wheel turns freely with a slight drag.  
Figure 14. Hydraulic Brake Actuator  
page 24 — MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13)  
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MaintenanCe — trailerS  
WaRnIng  
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.  
Figure 15. Adjustable Channel  
Table 4. Hydraulic Brake Troubleshooting  
Wheel Bearings  
symptom  
possible Cause  
Brake line broken or kinked?  
Brake lining glazed?  
solution  
Wheel bearings (Figure 16) must be inspected and  
lubricated once a year or 12,000 miles to insure safe  
operation of your trailer.  
No Brakes  
Repair or replace.  
Reburnish or replace.  
Correct weight.  
Trailer overloaded?  
Brake drums scored or  
grooved?  
Weak Brakes or  
Brakes Pull to  
One Side  
If trailer wheel bearings are immersed in water, they must  
be replaced.  
Machine or replace.  
Inflate all tires equally.  
Match tires.  
Tire pressure correct?  
Tires unmatched on the  
same axle?  
DangeR  
If trailer wheels are under water for a long period of  
time, wheel bearings may fail.If this is the case, service  
wheel bearings immediately.  
Brake components loose,  
bent or broken?  
Replace components.  
Locking Brakes  
Noisy Brakes  
Brake drums out-of-round?  
System lubricated?  
Replace.  
Lubricate.  
The possibility exists of the wheels falling off causing  
equipment damage and severe bodily harm even death!  
Brake components correct?  
Replace and correct.  
Brake lining thickness  
incorrect or not adjusted  
correctly?  
Install new shoes and  
linings.  
Dragging  
Brakes  
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.  
Enough brake fluid or correct  
fluid?  
Replace rubber parts  
fill with dot 4 fluid.  
aDJusTaBLe CHanneL  
Follow the steps below to disassemble the wheel hub and  
service the wheel bearings. See Figure 16.  
Your trailer may be equipped with an adjustable channel  
(Figure 15) that allows the coupler to be raised or lowered  
to a desired height. Periodically check the channel bolts  
for damage or loosening.  
BEARING  
WHEEL  
HUB  
OIL  
SEAL  
COTTER  
PIN  
BEARING  
CUP  
BEARING  
CUP  
NOTICE  
BEARING  
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.  
DUST  
CAP  
LUG  
NUT  
SPINDLE  
WASHER  
SPINDLE  
NUT  
Figure 16. Wheel Hub Components  
MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13) — page 25  
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MaintenanCe — trailerS  
After removing the dust cap, cotter pin, spindle nut and  
spindle washer, remove the hub to inspect the bearings  
for wear and damage.  
DangeR  
Improper weld repair will lead to early failure of the  
trailer structure and can cause serious injury or death.  
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.  
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.  
Replace seals that have nicks, tears or wear.  
WaRnIng  
Lubricate the bearings with a high quality EP-2  
automotive wheel bearing grease.  
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.  
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.  
LeaF suspensIOn  
The leaf suspension springs and associated components  
(Figure 17) 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.  
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  
(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.  
Check the 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!  
Figure 17. Leaf Suspension Components  
DangeR  
DangeR  
When performing trailer inspection and maintenance  
activities, you must jack up the trailer using jacks and  
jackstands.  
Worn or broken suspension parts can cause loss of  
control, damage to equipment and severe bodily injury,  
even death!  
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.  
Check suspension regularly.  
page 26 — MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13)  
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Safety guiDelineS — trailerS  
The following guidelines are intended to assist the operator  
in the operation and handling of a trailer.  
Shift your automatic transmission into a lower gear for  
city driving.  
Safety precautions should be followed at all times when  
operating a trailer. Failure to read, understand and follow  
the safety guidelines could result in injury to yourself and  
others.Loss of control of the trailer or tow vehicle can result  
in death or serious injury.  
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.  
COMMOn Causes FOR LOss OF TRaILeR  
To conserve fuel, don’t use full throttle to climb a hill.  
Instead, build speed on the approach.  
Driving too fast for the conditions (maximum speed when  
towing a trailer is 55 mph).  
Slow down for bumps in the road. Take your foot off the  
brake when crossing the bump.  
Overloading the trailer or loading the trailer unevenly.  
Trailer improperly coupled to the hitch.  
No braking on trailer.  
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.  
Not maintaining proper tire pressure.  
Not keeping lug nuts tight.  
DO nOT apply the brakes to correct extreme trailer  
swaying. Continued pulling of the trailer, and even slight  
acceleration, will provide a stabilizing force.  
Not properly maintaining the trailer structure.  
Ensure machine is towed level to tow vehicle.  
TRaILeR TOWIng guIDeLInes  
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.  
Recheck the load tiedowns to make sure the load will  
not shift during towing.  
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.  
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.  
Be aware of your trailer height, especially when  
approaching roofed areas and around trees.  
Use your mirrors to verify that you have room to change  
lanes or pull into traffic.  
Make regular stops, about once each hour. Confirm  
that:  
Use your turn signals well in advance. Allow plenty of  
stopping space for your trailer and tow vehicle.  
• Coupler is secure to the hitch and is locked.  
• Electrical connectors are secure.  
Allow plenty of stopping space for your trailer and tow  
vehicle.  
• There is appropriate slack in the safety chains.  
DO nOT drive so fast that the trailer begins to sway  
due to speed.  
• There is appropriate slack in the breakaway switch  
pullpin cable.  
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.  
• Tires are not visibly low on pressure.  
MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13) — page 27  
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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,  
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.  
WaRnIng  
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 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.  
• 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.  
Check rearview mirrors frequently to observe the trailer  
and traffic.  
neveR drive faster than what is safe.  
• Be sure the hitch components are tight before  
coupling the trailer to the tow vehicle.  
WaRnIng  
Driving too fast for severe road conditions can result in  
loss of control and cause death or serious injury.  
WaRnIng  
An improperly coupled trailer can result in death or  
serious injury.  
Decrease your speed as road, weather, and lighting  
conditions deteriorate.  
DO nOT move the trailer until:  
Always check for local trailer tow speed limits in your  
area.  
• The coupler is secured and locked to hitch.  
• The safety chains are secured to the tow vehicle.  
• The trailer jack(s) are fully retracted.  
WaRnIng  
Do not transport people on the trailer.The transport of  
people puts their lives at risk and may be illegal.  
DO nOT tow the trailer on the road until:  
• Tires and wheels are checked.  
• The trailer brakes are checked.  
COupLIng TO THeTOW veHICLe  
• The breakaway switch is connected 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. 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.  
• The load is secured to the trailer.  
• The trailer lights are connected and checked.  
WaRnIng  
Use of a hitch with a load rating less than the load rating  
of the trailer can result in loss of control and may 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.  
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.  
The trailer VIN tag contains the critical safetyinformation  
page 28 — MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13)  
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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.  
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.SeeTrailer  
Wiring Diagram section in this manual.  
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.  
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.  
It will take practice to learn how to back up a tow vehicle  
with a trailer 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.  
WaRnIng  
Improper electrical connection between the tow vehicle  
and the trailer will result in inoperable lights and can  
lead to collision.  
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.  
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.  
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.  
It takes longer to get up to speed, you need more room to  
turn and pass, and more distance 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.  
TRaILeR vInTag  
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.  
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.  
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.  
Figure A. Vehicle VIN Tag  
MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13) — page 29  
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Safety guiDelineS — trailerS  
To determine the “empty” or “net” weight of your trailer,  
weigh it on an axle scale. To nd 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.  
VI  
N
T
A
G
TOW veHICLe  
VIN TAG  
The towing hitch attached to your tow vehicle must have a  
capacity equal 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.  
Figure B. VIN Tag Location  
suspensIOn sYsTeM  
The trailer VIN Tag contains the following critical safety  
information for the use of your trailer.  
Sway bars, shock absorbers, heavy duty springs, heavy  
duty tires and other suspension components may be  
required to sufficiently tow the trailer and pump.  
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.  
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.  
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 GrossTrailerWeight).GVWR,  
GTWR and MGTW are all the same rating.  
sIDe vIeW MIRRORs  
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.  
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.  
psIC: The tire pressure (psi) measured when cold.  
HeavY DuTY FLasHeR  
vIn: The Vehicle Identification Number.  
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.  
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.  
eLeCTRICaL COnneCTOR  
An Electrical Connector connects the light and brake  
systems on the trailer to the light and brake controls on  
the towing vehicle.  
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Safety guiDelineS — trailerS  
eMeRgenCYFLaResanDTRIangLeReFLeCTORs  
BaLL HITCH COupLeR  
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.  
A ball hitch coupler (Figure 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.  
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.  
Figure C. Ball Hitch Coupler  
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.  
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 appropriate slack  
that will activate the system if the coupler connection  
comes loose.  
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.  
JaCKsTanD  
A 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”.  
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.  
COupLeR TYpes  
Two types of coupler used wit the trailer are discussed  
below.  
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 load rating of the hitch  
and ball is equal to or greater than that of your trailer.  
Ball Hitch Coupler  
Pintel Eye Coupler  
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  
MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13) — page 31  
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Safety guiDelineS — trailerS  
or is worn, the trailer can come loose from the tow vehicle  
and may cause death or serious injury.  
the trailer tongue. Wood or concrete blocks may also  
be used.  
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.  
Coupling theTrailer to theTowvehicle (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.  
The ball size and load rating (capacity) are marked on the  
ball. Hitch capacity is marked on the hitch.  
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.  
WaRnIng  
Coupler-to-hitch mismatch can result in uncoupling,  
leading to death or serious injury.  
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.  
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.  
Lower the trailer (Figure D) until the coupler fully engages  
the hitch ball.  
2-INCH  
TRAILER  
WaRnIng  
COUPLER  
TOW  
VEHICLE  
A worn, cracked or corroded hitch ball can fail while  
towing and may result in death or serious injury.  
Before coupling trailer, inspect the hitch ball for wear,  
corrosion and cracks.  
2-INCH  
BALL  
Replace worn or damaged hitch ball.  
Figure D. Ball Hitch Coupling Mechanism  
WaRnIng  
Engage the coupler locking mechanism. In the engaged  
position, the locking mechanism securely holds the  
coupler to the hitch ball.  
A loose hitchball nut can result in uncoupling, leading  
to death or serious injury.  
Be sure the hitch ball is tight to the hitch before coupling  
the trailer.  
Insert a pin or lock through the hole in the locking  
mechanism.  
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.  
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.  
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.  
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.  
The bottom surface of the coupler must be above the top  
of the hitch ball. Use the tongue jackstand to support  
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Safety guiDelineS — trailerS  
Breakaway Brake system  
NOTICE  
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 trailer’s axles, the trailer/tow vehicle combination will  
come to a controlled stop.  
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.  
Breakaway Lever  
Connect Cable to  
Tow Vehicle  
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 E.  
TOW  
Hydraulic Actuator  
Figure F. Breakaway Brake System  
VEHICLE  
Breakaway Cable surge Brake system  
The breakaway brake system includes 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.  
TRAILER  
TONGUE  
IMPORTANT!  
SAFETY CHAIN  
CROSS BOTH  
MASTER LINK  
SAFETY CHAINS  
WaRnIng  
Figure E. Attaching Safety Chain (Ball Hitch)  
• An ineffective breakaway brake system can result in  
a runaway trailer, leading to death or serious injury,  
if the coupler or ball hitch fails.  
• 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).  
• Connect the breakaway cable to the tow vehicle and  
NOT to the hitch, ball or support.  
• 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  
• 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.  
.
WaRnIng  
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.  
NOTICE  
DO NOT tow the trailer with the breakaway brake  
system ON because the brakes will overheat which  
can result in permanent brake failure.  
• 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.  
NOTICE  
• Cross chains underneath hitch and coupler with  
enough slack to permit turning and to hold tongue  
up, if the trailer comes loose.  
Replace the breakaway brake battery (if equipped) at  
intervals specified by manufacturer.  
MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13) — page 33  
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Safety guiDelineS — trailerS  
ConnectingTrailer Lights  
pInTLe HITCH COupLeR  
Connect the trailer lights to the tow vehicle’s electrical  
system using the electric connectors at the front of the  
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:  
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.”  
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).  
WaRnIng  
Improper electrical connection between the tow vehicle  
and the trailer will result in inoperable lights and electric  
brakes, and can lead to collision.  
Figure G. Pintle Hitch Coupler  
A pintle hitch trailer may be fitted with a tongue jackstand  
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:  
• 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.  
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.  
uncoupling the Ball Hitch  
Follow these steps to uncouple ball hitch from tow  
vehicle:  
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.  
Block trailer tires to prevent the trailer from rolling, before  
jacking the trailer up.  
Disconnect the electrical connector.  
pintle Coupler and pintle Hook  
Disconnect the breakaway brake switch cable. Promptly  
replace the pullpin in the switchbox.  
Before each tow, check the locking device that secures the  
coupler to the pintle hook assembly.  
Before extending jackstand, make certain the ground  
surface below the jackstand foot will support the tongue  
load.  
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 SAE30W  
motor oil to prevent rust and help ensure proper operation  
of the latching mechanism.  
Rotate the jackstand handle (or crank) clockwise. This  
will slowly extend the jack and transfer the weight of the  
trailer tongue to the jack.  
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  
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Safety guiDelineS — trailerS  
the ball andcoupler system.All bent or broken coupler parts  
must be replaced before towing the trailer.  
WaRnIng  
A defective pintle hitch not properly fastened can result  
in uncoupling, leading to death or serious injury.  
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).  
Be sure the pintle hook is securly tighten to the tow  
vehicle before coupling the trailer.  
CouplingTrailer to Tow vehicle (pintle Coupler)  
IT IS ESSENTIAL THAT THE PINTLE HITCH BE OF THE  
SAME SIZE AS THE PINTLE COUPLER.  
Slowly back up the tow vehicle so that the pintle  
hitch hook is near or aligned under the pintle eye ring  
coupler.  
The coupler size and load rating (capacity) are marked on  
the coupler. Hitch capacity is marked on the hitch.  
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.  
WaRnIng  
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.  
OPEN the pintle hook locking mechanism (Figure H).  
Place the hook inside the eye coupler.CLOSE the pintle  
hook mechanism.  
TRAILER  
Be sure the SIZE of the pintle hitch hook matches the  
size of the pintle eye coupler.  
TONGUE  
PINTLE  
HOOK  
TOW  
VEHICLE  
WaRnIng  
SAFETY CHAIN  
MASTER LINK  
A worn, cracked or corroded pintle hitch hook can  
fail while towing, and may result in death or serious  
injury.  
PINTLE  
RING “EYE”  
Before coupling trailer, inspect the pintle hitch hook for  
wear, corrosion and cracks.  
SAFETY  
CHAIN  
IMPORTANT!  
CROSS BOTH  
SAFETY CHAINS  
Replace worn or damaged pintle hitch hook.  
Figure H. Attaching Safety Chain (Pintle Hitch)  
Rock the pintle eye coupler to make sure it is secured  
tightly to the hitch.  
Insert a pin or lock through the hole in the locking  
mechanism.  
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 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.  
Be sure the coupler is secured tightly to the tongue of the  
trailer. All coupler fasteners must be visibly solid against  
the trailer frame.  
Raise the bottom surface of the coupler 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.  
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.  
MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13) — page 35  
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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  
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.  
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.  
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.  
WaRnIng  
Lug nuts are prone to loosen after initial installation,  
which can lead to death or serious injury.  
Uneven tread wear can be caused by tire imbalance, axle  
misalignment or incorrect inflation.  
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.  
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.  
WaRnIng  
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.  
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.  
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.  
WaRnIng  
Improper tire pressure can result in a blowout and loss  
of control, which can lead to death or serious injury.  
Since trailer wheels and lug nuts (or bolts) are subjected  
to greater side loads than automobile wheels, they are  
more prone to loosen. Before each tow, check to make  
sure they are tight.  
Be sure tires are inflated to pressure indicated on side  
wall before towing trailer.  
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.  
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 half of the left (road) side of the unit.  
This certification/VIN label will indicate the trailer’s 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.  
WaRnIng  
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 — MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13)  
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Safety guiDelineS — trailerS  
There is a vehicle placard (Figure I) located in the same  
Determining Load Limit of Tow vehicle  
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.  
step 1.  
Locate the statement, “The combined weight of occupants  
and cargo should never exceed XXX lbs.,on your vehicle’s  
placard.  
TIRE AND LOADING INFORMATION  
step 2.  
The weight of cargo should never exceed XXX kg. Or XXX lbs.  
Determine the combined weight of the driver and  
passengers who will be riding in your vehicle.  
TIRE  
SIZE  
COLD TIRE PRESSURE  
SEE OWNER’S  
MANUAL FOR  
ADDITIONAL  
INFORMATION  
FRONT  
REAR  
SPARE  
step 3.  
Subtract the combined weight of the driver and passengers  
from XXX kilograms or XXX pounds.  
Figure I. Trailer Tire Placard  
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.  
step 4.  
The resulting figure equals the available amount of cargo  
and luggage capacity. For example, if the “XXX” amount  
equals 1400 lbs. and there will be five 150 lb. passengers  
in your vehicle, the amount of available cargo and luggage  
capacity is 650 lbs. (1400-750 (5 x 150) = 650 lbs.).  
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.  
step 5.  
Determine 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.  
Perform the following steps to determine the load limit of  
your trailer.  
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:  
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 I). 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’sVIN (Certification) label at the left front of the trailer  
(See Figure I).  
Improve vehicle handling.  
Help protect you and others from avoidable breakdowns  
and accidents.  
Improve fuel economy.  
Increase the tire life.  
MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13) — page 37  
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Safety guiDelineS — trailerS  
Use the information contained in this section to make tire  
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.  
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.  
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 inTable A.Note:You may  
not find this information on all tires because it is not required  
by law.  
TIRe FunDaMenTaLs  
Federallawrequirestiremanufacturerstoplacestandardized  
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.  
Table a. speed Rating  
Letter Rating  
speed Rating  
99 mph  
Q
R
S
T
106 mph  
112 mph  
118 mph  
U
H
V
W
Y
124 mph  
130 mph  
149 mph  
168* mph  
186* mph  
Figure J. Standard Tire Sidewall Information  
u.s. DOTTire 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.  
p: The “P” indicates the tire is for passenger vehicles.  
next number: This three-digit 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.  
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 materials in the tire, which include steel,  
nylon, polyester, and others.  
p:The “R” 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.  
Maximum Load Rating: This number indicates the  
maximum load in kilograms and pounds that can be carried  
by the tire.  
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  
owner’s 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.  
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.  
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Safety guiDelineS — trailerS  
Load Range: This information identifies the tire’s load-  
carrying capabilities and its inflation limits.  
uniform Tire Quality grading standards (uTQgs)  
Treadwear 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.  
Tire safety Tips  
Slow down if you have to go over a pothole or other  
object in the road.  
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 “AA”,”A”, “B”, and “C”.  
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 weekly during use to insure  
the maximum tire life and tread wear.  
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 “A”, “B”, or “C”.  
DO nOT bleed air from tires when they are hot.  
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.  
Refer to Figure K for additional tire information for light  
trucks.  
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.  
Figure K. UTQGS Tire Information  
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.  
Replacing Worn or Damaged Tires  
sT: An “ST” is an indication the tire is for trailer use only.  
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.  
Max. Load Dual kg (lbs) at kPa (psi) Cold: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.  
MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13) — page 39  
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Safety guiDelineS — trailerS  
Table B below will help pinpoint the causes and solutions  
of tire wear problems.  
NOTICE  
neveR use an pneumatic air gun to tighten wheel  
lug nuts.  
Table B. Tire Wear Troubleshooting  
Cause  
Wear pattern  
solution  
Over-tightening lug nuts will result in breaking the studs  
or permanently deforming the mounting stud holes in  
the wheels.  
Adjust pressure to particular  
load per tire manufacturer.  
Center Wear Over inflation.  
Edge Wear Under inflation.  
Adjust pressure to particular  
load per tire manufacturer.  
WaRnIng  
Make sure load does not  
exceed axle rating.  
Align wheels.  
Loss of camber  
Side Wear  
Lug nuts are prone to loosen after initial installation,  
which can lead to death or serious injury. Check all  
wheel lug nuts periodically.  
or overloading.  
Toe Wear  
Cupping  
Incorrect toe-in.  
Out-of-balance.  
Align wheels.  
Lug nut Torque Requirements  
Check bearing adjustment  
and balance tires.  
It is 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:  
Wheel lockup and Avoid sudden stops when  
tire skidding. possible and adjust brakes.  
Flat Spots  
WaRnIng  
1. Start all wheel lug nuts by hand.  
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  
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.  
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.  
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  
Wheel Rims  
If 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 spin  
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.  
Figure L. Wheel Lug Nuts Tightening Sequence  
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Safety guiDelineS — trailerS  
Replace any broken or burned-out lamps as necessary.  
Check the wire harness for cuts, fraying or other damage.  
If it needs replacing, contact your dealer.  
Table C. Tire Torque Requirements  
First pass  
FT-LBs  
second pass  
FT-LBs  
Third pass  
FT-LBs  
Wheel size  
12"  
13"  
14"  
15"  
16"  
20-25  
20-25  
20-25  
20-25  
20-25  
35-40  
35-40  
50-60  
50-60  
50-60  
50-65  
WaRnIng  
50-65  
Improper operating taillights, stoplights and turn signals  
can cause collisions.  
90-120  
90-120  
90-120  
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.  
Figure M. Trailer to Tow Vehicle Wiring Diagram  
MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13) — page 41  
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trOubleShOOting  
Table 5. Lamp Troubleshooting  
possible Cause  
symptom  
solution  
Test the lamp in a fixture which is operating properly.  
Replace if necessary.  
Lamp Burned Out?  
Inspect lamp base to see if there is arcing at center  
contact button. Tighten lamp snugly. Check socket for  
damage. Replace if defective.  
Lamp Loose in Socket?  
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.  
Defective Ballast?  
Low Voltage?  
Check line voltage at ballast input. Voltage 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  
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  
and including the horizontal and a BD can be operated  
base down vertical to, approaching, but not including  
the horizontal. A lamp operated beyond the specified  
position may not start.  
Improper Lamp Operating  
Position (Metal Halide only)?  
HID lamps (High Pressure Sodium, Metal Halide,  
Mercury Vapor) require from 4 to 8 minutes cool-down  
time before restarting. Switch off breaker and allow  
lamp to cool.  
Lamp has been Operating: Cool  
Down Time Insufficient?  
Improper ballasting can cause flickering or erratic  
operation. In the start-up period the lamp may ignite,  
start to warm up and then extinguish (cycle).  
Improper Ballast?  
Lamp flickers and goes  
out intermittent or  
cycling.  
Under certain conditions new lamps may "cycle".  
Usually after 3 tries to start at 30 to 60 second  
intervals, lamps will stabilize and operate satisfactorily.  
New Lamp?  
Defective Lamp?  
Replace lamp.  
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trOubleShOOting  
Table 5. Lamp Troubleshooting (continued)  
possible Cause  
symptom  
solution  
Lamp starts slowly  
(ARC does not strike  
when switch is first  
turned on)  
Lamp may glow for extended period of time. Replace after  
checking voltage and ballast.  
Defective Lamp?  
Circuit breaker trips on  
lamp start-up  
Short Circuit or Ground?  
Check wiring against diagram. Check for shorts or ground.  
Normal Lamp  
Depreciation?  
Replace 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.  
Defective Ballast?  
Lamp light output low  
Check voltage at ballast input. Voltage should be within 10%  
of nameplate rating. Check wiring connections for voltage  
loss. Check socket contact point.  
Wrong Voltage?  
Improper Ballast?  
Check ballast nameplate against lamp data.  
Lamp output and brightness decreases and color changes  
slightly as lamps age. Spot replacement with new lamps  
may cause noticeable differences in lamp colors. Group  
replacement minimizes color differences.  
Normal Lamp  
Depreciation?  
Lamp colors different.  
Dirty fixtures will cause lamps to appear different in color.  
Clean fixture.  
Dirty Fixture?  
Wrong Lamp?  
Check data on lamps which appear different in color. Replace  
with correct color lamp.  
Over Voltage from Power  
Supply?  
Check voltage at ballast. Check for current or voltage surges.  
Check for shorted capacitors and replace if defective.  
ARC tube discolored or  
swollen.  
Lamp operated on ballast designed for higher wattage lamp.  
Check ballast nameplate against lamp data.  
Improper Ballast?  
Lamp Damaged?  
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 too firmly in socket or scoring of glass where socket  
inadvertently touches the lamp bulb. Look for broken arc tube  
or loose metal parts. Replace lamp. (Bulb leads will cause  
oxidation of metal parts.)  
Short lamp life.  
Ballast nameplate data should agree with lamp line voltage  
and lamp use. If improper ballast is used, the lamp life will be  
shortened. A mismatch may also cause the ballast to fail.  
Improper Ballast?  
MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13) — page 43  
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trOubleShOOting  
6. If the lamp ignites after plugging it into a working  
receptacle, continue with step 7.  
LaMpTROuBLesHOOTIng guIDe  
Use the following procedure and wiring diagrams on the  
next pages to determine which of the four lamps is not  
functioning:  
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.  
Connections  
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.  
1. Make sure that lamp #1 power cable is plugged into  
the J1 connector on the T-Bar assembly.  
2. Make sure that lamp #2 power cable is plugged into  
the J2 connector on the T-Bar assembly.  
9. If no output voltage is present, the circuit breaker is  
defective and needs to be replaced.  
3. Make sure that lamp #3 power cable is plugged into  
the J3 connector on the T-Bar assembly.  
10. If the correct output voltage is present then it can be  
assumed that the generator is working correctly and  
the correct voltage (120 VAC) is being supplied to the  
ballast.Then it can be assumed that the ballast for that  
lamp is defective. Replace ballast.  
4. Make sure that lamp #4 power cable is plugged into  
the J4 connector on the T-Bar assembly.  
5. Make sure that lamp #5 power cable is plugged into  
the J5 connector on the T-Bar assembly.  
6. Make sure that lamp #6 power cable is plugged into  
the J6 connector on the T-Bar assembly.  
Ballast Removal  
1. Remove the power cable from the generator, and make  
sure that no voltage is being supplied to the ballast  
compartment.  
NOTICE  
2. Remove the four screws securing the ballast cover,  
and remove cover.  
MLT20DCA (4-lamp) only uses receptacles J1 through  
J4.  
3. Make sure to discharge the ballast capacitor.  
starting  
4. 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. Start the generator and verify that there are no  
abnormal sounds.  
2. Turn CB1 thru CB6 circuit breakers to the ON position.  
3. Wait a few minutes and determine which lamp is not  
igniting.  
4. 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.  
5. 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.  
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nOteS  
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eleCtrOniC COMpOnent lOCatOr (Mlt20DCa)  
S
J1  
R
J2  
Q
J3  
P
J4  
LAMP 1  
LAMP 2  
LAMP 4  
LAMP 3  
O
A
BLACK  
U
RED  
V
GREEN  
WOHITE  
E
C
D
B
E
E
N
GR  
D
RE  
V
WOHITE  
K
L
AC  
B U  
J
K
L
M
F
G
H
I
N
NOTICE  
Reference MLT20DCA (4-lamp) wiring diagram on  
succeeding pages.  
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eleCtrOniC COMpOnent lOCatOr (Mlt20DCa6)  
T
U
V
W
X
Y
A1  
A
BLACK  
WHITE  
RED  
GREEN  
U
V
O
G
E
C
F
D
B
N
EE  
GR  
D
RE  
V
ITE  
WH  
O
K
AC  
BL  
U
N
O
P
Q
R
S
H
J
I
L
K
M
Z
NOTICE  
Reference MLT20DCA6 (6-lamp) wiring diagram on  
succeeding pages.  
MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13) — page 47  
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wiring DiagraM (Mlt20DCa)  
OUTPUT TERMINAL PANEL  
REAR CONNECTIONS  
GROUND CONNECTION  
MUST BE USED  
AT ALL TIMES  
BLACK  
WHITE  
RED  
GREEN  
U
O
V
A
GREEN 14 AWG  
NEU.  
L1  
L2  
GND.  
GROUND  
STUD  
GREEN 16 AWG  
2-POLE, 15 AMP  
CIRCUIT BREAKER  
A
B  
RED 14 AWG  
BLK 14 AWG  
CB1  
B
BLK 14 AWG  
RED 14 AWG  
C
CB2  
C
2-POLE, 15 AMP  
CIRCUIT BREAKER  
RED 14 AWG  
BLUE 14 AWG  
D
E  
CB3  
D
BLK 14 AWG  
YELLOW 14 AWG  
CB4  
E
WHITE 12 AWG  
WHITE 12 AWG  
F  
G
NOTICE  
Reference MLT20DCA (4-lamp) locator diagram on  
preceeding pages.  
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wiring DiagraM (Mlt20DCa)  
T-BAR ASSEMBLY  
P/N 19954  
J1  
(LAMP 1)  
J2  
(LAMP 2)  
J3  
(LAMP 3)  
J4  
(LAMP 4)  
BLK  
RED  
WHT  
YEL  
WHT  
WHT  
BLUE  
WHT  
R
S
Q
P
GRN  
GRN  
GRN  
GRN  
GREEN 16 AWG  
A
B  
7-WIRE COIL CORD  
P/N 29433  
C1  
F
BALLAST #1  
(LAMP 1)  
BLK 14 AWG  
24µF@480V  
CAPACITOR  
120V IN  
OUTPUT  
NEU.  
J
BLK  
16 AWG  
RED 16 AWG  
4 LAMP BALLAST ASSEMBLY  
P/N 49784 (MLT20DCA)  
R1  
1
O
C2  
G
RED 14 AWG  
BALLAST #2  
120V IN  
24µF@480V  
CAPACITOR  
C
NOTES:  
OUTPUT  
NEU.  
RESISTOR IS INTERNALLY  
INSTALLED WITHIN THE CAPACITOR.  
K
1
RED  
16 AWG  
RED 16 AWG  
NEUTRAL BUS  
TB1 N  
C3  
H
BLUE 14 AWG  
WHT 14 AWG  
WHT 14 AWG  
BALLAST #3  
YEL  
120V IN  
24µF@480V  
CAPACITOR  
D
OUTPUT  
NEU.  
L
BLUE  
16 AWG  
RED 16 AWG  
YEL 16 AWG  
C4  
I
YELLOW 14 AWG  
YEL 16 AWG  
YEL 16 AWG  
BALLAST #4  
120V IN  
E
24µF@480V  
CAPACITOR  
OUTPUT  
NEU.  
M
YEL 16 AWG  
RED 16 AWG  
YEL 16 AWG  
WHITE 12 AWG  
WHITE 12 AWG  
F  
G
MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13) — page 49  
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wiring DiagraM (Mlt20DCa6)  
OUTPUT TERMINAL PANEL  
REAR CONNECTIONS  
NOTICE  
GROUND CONNECTION  
MUST BE USED  
AT ALL TIMES  
Reference MLT20DCA6 (6-lamp) locator diagram on  
preceeding pages.  
BLACK  
WHITE  
RED  
GREEN  
U
O
V
A
GREEN 14 AWG  
NEU.  
L1  
L2  
GND.  
GROUND  
STUD  
GREEN 16 AWG  
2-POLE, 15 AMP  
CIRCUIT BREAKER  
A
B  
RED 14 AWG  
BLK 14 AWG  
CB1  
B
BLK 14 AWG  
RED 14 AWG  
C
CB2  
C
2-POLE, 15 AMP  
CIRCUIT BREAKER  
RED 14 AWG  
BLUE 14 AWG  
D
E  
CB3  
D
BLK 14 AWG  
YELLOW 14 AWG  
CB4  
E
2-POLE, 15 AMP  
CIRCUIT BREAKER  
RED 14 AWG  
ORANGE 14 AWG  
F  
CB5  
F
BLK 14 AWG  
PURPLE 10 AWG  
G
CB6  
G
WHITE 10 AWG  
WHITE 10 AWG  
H
I  
page 50 — MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13)  
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wiring DiagraM (Mlt20DCa6)  
T-BAR ASSEMBLY  
P/N 49721  
WHT  
J1  
(LAMP 1)  
J2  
(LAMP 2)  
J3  
(LAMP 3)  
J4  
(LAMP 4)  
J5  
(LAMP 5)  
J6  
(LAMP 6)  
WHT  
WHT  
WHT  
WHT  
BLK  
RED  
BLUE  
YEL  
ORG  
PURPLE  
Y
V
W
X
T
U
GRN  
GRN  
GRN  
GRN  
GRN  
GRN  
GREEN 16 AWG  
A
B  
10-WIRE COIL CORD  
P/N 49609  
C1  
H
BALLAST #1  
(LAMP 1)  
BLK 14 AWG  
24µF@480V  
CAPACITOR  
120V IN  
OUTPUT  
NEU.  
N
BLK  
16 AWG  
RED 16 AWG  
6 LAMP BALLAST ASSEMBLY  
P/N 49785 (MLT20DCA6)  
R1  
1
A1  
C2  
I
RED 14 AWG  
BALLAST #2  
120V IN  
24µF@480V  
CAPACITOR  
C
NOTES:  
OUTPUT  
NEU.  
RESISTOR IS INTERNALLY  
INSTALLED WITHIN THE CAPACITOR.  
O
1
RED  
16 AWG  
RED 16 AWG  
NEUTRAL BUS  
Z
TB1  
C3  
J
BLUE 14 AWG  
WHT 14 AWG  
WHT 14 AWG  
WHT 14 AWG  
BALLAST #3  
YEL  
120V IN  
24µF@480V  
CAPACITOR  
D
OUTPUT  
NEU.  
P
BLUE  
16 AWG  
RED 16 AWG  
YEL 16 AWG  
C4  
K
YELLOW 14 AWG  
YEL 16 AWG  
YEL 16 AWG  
BALLAST #4  
120V IN  
E
24µF@480V  
CAPACITOR  
OUTPUT  
NEU.  
Q
YEL 16 AWG  
RED 16 AWG  
YEL 16 AWG  
C5  
L
BLK 14 AWG  
BALLAST #5  
120V IN  
24µF@480V  
CAPACITOR  
F
OUTPUT  
NEU.  
R
RED 16 AWG  
ORG 16 AWG  
YEL 16 AWG  
C6  
M
BLK 14 AWG  
BALLAST #6  
120V IN  
24µF@480V  
CAPACITOR  
G
OUTPUT  
NEU.  
S
RED 16 AWG  
PURPLE 16 AWG  
YEL 16 AWG  
WHITE 10 AWG  
WHITE 10 AWG  
H
I  
MLT20 seRIes LIgHT TOWeR • OpeRaTIOn ManuaL — Rev. #0 (01/18/13) — page 51  
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OperatiOn Manual  
HERE’S HOW TO GET HELP  
PLEASE HAVE THE MODEL AND SERIAL  
NUMBER ON-HAND WHEN CALLING  
United StateS  
Multiquip Corporate Office  
MQ Parts Department  
18910 Wilmington Ave.  
Carson, CA 90746  
Contact: [email protected]  
Tel. (800) 421-1244  
Fax (310) 537-3927  
800-427-1244  
310-537-3700  
Fax: 800-672-7877  
Fax: 310-637-3284  
Service Department  
Warranty Department  
800-421-1244  
310-537-3700  
Fax: 310-537-4259  
Fax: 310-943-2238  
800-421-1244  
310-537-3700  
Fax: 310-943-2249  
Technical Assistance  
800-478-1244  
mexico  
United Kingdom  
MQ Cipsa  
Multiquip (UK) Limited Head Office  
Carr. Fed. Mexico-Puebla KM 126.5  
Momoxpan, Cholula, Puebla 72760 Mexico  
Contact: [email protected]  
Tel: (52) 222-225-9900  
Unit 2, Northpoint Industrial Estate, Tel: 0161 339 2223  
Fax: (52) 222-285-0420 Globe Lane,  
Dukinfield, Cheshire SK16 4UJ  
Contact: [email protected]  
Fax: 0161 339 3226  
Canada  
Multiquip  
4110 Industriel Boul.  
Laval, Quebec, Canada H7L 6V3  
Contact: [email protected]  
Tel: (450) 625-2244  
Tel: (877) 963-4411  
Fax: (450) 625-8664  
© COPYRIGHT 2013, 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 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:  
pn 49838  
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