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Generac Power Systems MAGNUM MLT4200IVF4, Owner'S Manual, Page: 41 / 56

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Generac Power Systems MAGNUM MLT4200IVF4 Owner'S Manual Download Page 41

Wiring Diagrams

Owner’s Manual for MLT4200IVF4 Light Tower

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Section 6: Wiring Diagrams

Mast Junction Box Wiring and Light Connections

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Summary of Contents for MAGNUM MLT4200IVF4

Page 1: ...Owner s Manual Light Tower MLT4200IVF4 SAVE THIS MANUAL FOR FUTURE REFERENCE For technical assistance contact www generacmobileproducts com Technical Support 1 800 926 9768 ...

Page 2: ...sponsibility to perform all safety checks to verify that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by a Generac Mobile Products Authorized Service Dealer Normal maintenance service and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship within the terms of ...

Page 3: ...17 Prestart Checklist 18 Raising the Mast 18 Preparing for Start Up 19 Select AUTO or MANUAL Mode 19 Configure for Intended Use 19 Emergency Stop Switch 19 Engine Break In Requirements 20 Manually Starting the Unit 20 Auto Remote Starting of the Unit 20 Light Operation 21 Engine Derating 21 Wet Stacking 21 Voltage Regulation 21 Customer Convenience Outlets 21 Remote Start Terminal Block 22 Transfe...

Page 4: ...ng the Lights 36 Section 6 Wiring Diagrams Mast Junction Box Wiring and Light Connections 37 AC Wiring 38 AC Wiring Receptacle Panel 39 AC Wiring Receptacle Panel Options 1 of 2 40 AC Wiring Receptacle Panel Options 2 of 2 41 DC Wiring 42 DC Wiring for Electric Winch 43 DC Wiring for Optional Equipment 44 Trailer Lights Wiring 45 ...

Page 5: ...cating a dealer go to www generacmobleproducts com parts service find service When contacting an Generac Mobile Products Authorized Service Dealer about parts and service always supply the complete model number and serial number of the unit as given on its data decal located on the unit Record the model number and serial numbers in the spaces provided on the inside front cover of this manual Safet...

Page 6: ...ipment and could result in death or serious injury 000215 000139 WARNING Risk of burns Allow engine to cool before draining oil or coolant Failure to do so could result in death or serious injury 000105 DANGER Explosion and Fire Fuel and vapors are extremely flammable and explosive Add fuel in a well ventilated area Keep fire and spark away Failure to do so will result in death or serious injury 0...

Page 7: ...ury 000188 DANGER Electrocution Do not wear jewelry while working on this equipment Doing so will result in death or serious injury DANGER Electrocution DO NOT use the unit if electrical cord is cut or worn through Doing so will result in death or serious injury 000263a 000188 DANGER Electrocution Do not wear jewelry while working on this equipment Doing so will result in death or serious injury 0...

Page 8: ... missing Ambient air temperature is above 120 F 49 C Operating Safety Positioning the Unit The area immediately surrounding the unit should be dry clean and free of debris Position and operate the unit on a firm level surface If the unit is equipped with a frame grounding stud follow the National Electrical Code NEC state and local regulations when connecting Starting the Unit 000192 DANGER Explos...

Page 9: ...ortant operating instructions and warn of dangers and hazards Wear heavy leather gloves when handling winch cables Never let cables slip through bare hands Only use mild soap and water to clean the lens covers Other chemicals may damage the lens covers Make sure slings chains hooks ramps jacks and other types of lifting devices are attached securely and have enough weight bearing capacity to lift ...

Page 10: ... Tires Check trailer tires for wear and proper inflation Verify wheel lug nuts are present and tightened to the specified torque Safe Towing Techniques Practice turning stopping and backing up in an area away from heavy traffic prior to transporting the unit Maximum recommended speed for highway towing is 45 mph 72 km h Recommended off road towing speed is 10 mph 16 km h or less depending on terra...

Page 11: ...ltage volts 120 240 single phase Output Amperes 120V 240V amperes 167 83 Frequency Hz Hertz 60 Power Factor 1 1Ø Sound 23ft at prime dB A 70 Weights Dry Weight lbs kg 2067 938 Operating Weight lbs kg 2362 1071 Capacities Fuel Tank Volume gal L 50 190 Usable Fuel Volume gal L 50 190 Coolant including engine qt L 12 11 3 Oil including filter qt L 8 0 7 6 Maximum Run Time hours 23 8 AC Distribution C...

Page 12: ...nual for MLT4200IVF4 Light Tower Unit Dimensions Figure 2 1 Unit Dimensions Specifications are subject to change without notice A B C D E MLT4200IVF4 115 in 2 92 m 107 in 2 71 m 25 ft 7 6 m 68 in 1 73 m 140 in 3 56 m D B A E C 004760 ...

Page 13: ...6B Manufactured by Generac Mobile Products LLC 920 361 4442 800 926 9768 VIN Tag TIRE AND LOADING INFORMATION RENSEIGNEMENTS SUR LES PNEUS ET LE CHARGEMENT SEE OWNER S MANUAL FOR ADDITIONAL INFORMATION VOIR LE MANUEL DE L USAGER POUR PLUS DE RENSEIGNEMENTS MANUFACTURED BY FABRIQUE PAR Generac Mobile Products LLC DATE 00 0000 GVWR PNBV 000KG 0000LBS COLD INF PRESS PRESS DE V I N N I V 0000000000000...

Page 14: ...s Figure 2 3 Component Locations A Radiator Access G Rear Jack B Engine Battery Access H Receptacle Pane C Fork Lift Pockets I Tongue Jack D Central Lift Point J Control Panel Access E Fuel Fill Access K Emergency Stop Switch F Leveling Jack Outrigger A B C C D E F B G H F I J K 004762 ...

Page 15: ... MLT4200IVF4 Light Tower 11 Control Panel Figure 2 4 Control Panel A Power Zone DLA D AC Light Breakers 4 B Main Circuit Breaker E DC Breaker C Control Power Switch ON ON NEUTRAL BONDED TO FRAME DC BREAKER MAIN BREAKER 240V E D A B C 00896 ...

Page 16: ... LCD Window This window displays the various operating screens By viewing these screens the operator can monitor both the engine and generator status while the unit is running B Select LED This LED illuminates when the unit is running in AUTO mode C Start LED This LED illuminates when the unit is running in MANUAL mode D Start Button This button starts the engine if there are no shutdown errors an...

Page 17: ...If the unit is in AUTO mode the Home screen may also display whether or not the scheduler is enabled Figure 2 7 Home Screen Engine Screen See Figure 2 8 The Engine screen displays battery voltage oil pressure coolant temperature and fuel level Figure 2 8 Engine Screen VBAT Displays the engine battery voltage A normal reading is 12 14V on 12 volt systems and 24 26V on 24V systems with the engine ru...

Page 18: ...at the top of the screen Alarms Screen See Figure 2 12 The Alarms screen displays all the alarms warnings and engine Diagnostic Trouble Code DTC faults When an alarm occurs the controller automatically switches to this screen and remains there until the alarm is cleared The Stop LED also flashes Figure 2 12 Alarms Screen Warnings are non critical alarm conditions and do not affect the operation of...

Page 19: ...air filter Figure 2 13 Maintenance Screen Event Log Screen See Figure 2 14 The controller s event log displays a list of the last 15 recorded electrical trips or shutdown events and the engine hours at which they occurred Once the log is full any subsequent electrical trip or shutdown alarm overwrites the oldest entry in the log Therefore the log always contains the most recent shutdown alarms Fig...

Page 20: ...4 Light Tower About Screen See Figure 2 15 The About screen contains information about the controller such as the controller s date and time the product and USB identification number and the application and engine version Figure 2 15 About Screen 003783 ...

Page 21: ...ulations 5 Pull the locking pin D on the outrigger E and pull each outrigger out until the spring loaded locking pin snaps back into place Pull the locking pin on the outrigger jack and rotate each jack 90 so the jack pad is facing down Install the locking pin 6 Pull the locking pin on the rear jack F and rotate the jack 90 Install the locking pin Rotate the jack handle clockwise to start leveling...

Page 22: ...Verify all covers are in place and secure Verify the emergency stop switch is pulled out Raising the Mast 1 Set up and level the unit See Light Tower Setup 2 See Figure 3 2 Check the mast cables for excessive wear or damage Verify the cables are properly centered in each pulley A Check the electrical cord for damage Figure 3 2 Pulley Locations 3 Press and hold the winch control switch B upward to ...

Page 23: ...uel consumption LED Lights and Export Power Turn the 240V outlet breaker ON and Load Sense OFF The engine will run at high speed for powering high amperage equipment LED Lights and Export Power with Load Sense Turn the 240V outlet breaker ON and Load Sense ON The engine will run at high speed when detecting applied load s such as hand tools and low amperage equipment Table 3 1 illustrates the four...

Page 24: ... its governed operating speed 4 If the engine does not start after the first cranking attempt the engine will pause for 15 seconds to allow the starter to cool The controller backlight will go out The engine will make two more attempts to start for a total of three crank cycles 5 If the engine does not start and run within three starting cycles the LCD screen will display the Fail to Start alarm T...

Page 25: ... run at less than 30 of its full load capacity causing unburned fuel to accumulate in the exhaust system Wet stacking can be detected by continuous black exhaust when the unit is under a constant load It can also cause fouling of injectors and buildup on engine valves Diesel engines operate properly when applied loads are between 30 and 100 capacity Appropriate generator sizing is determined by th...

Page 26: ...EN If the contacts on a remote switch are closed the engine will crank and start when AUTO mode is entered Attach the switch leads to the two unused terminals on the unit s remote start terminal block For more information refer to Auto Remote Starting of the Unit Figure 3 7 Remote Start Terminal Block Transfer Switch When the unit is used as a standby power supply it must be equipped with a transf...

Page 27: ...d STOP RESET O buttons to change the time Holding down either button will change the time faster Press the AUTO button to save the time 5 Adjust the parameter number to adjust the day of the week and press the AUTO button to enter it Press the MANUAL START I and STOP RESET O button to change to the desired day and press the AUTO button to save it NOTE Only one day can be chosen per event if parame...

Page 28: ...1 2 3 4 919 Scheduler 4 Duration 0 00 00 920 Scheduler 5 Start Time 0 00 00 921 Scheduler 5 Start Day 0 1 Monday 922 Scheduler 5 Start Week 1 2 3 4 923 Scheduler 5 Duration 0 00 00 924 Scheduler 6 Start Time 0 00 00 925 Scheduler 6 Start Day 0 1 Monday 926 Scheduler 6 Start Week 1 2 3 4 927 Scheduler 6 Duration 0 00 00 928 Scheduler 7 Start Time 0 00 00 929 Scheduler 7 Start Day 0 1 Monday 930 Sch...

Page 29: ... following steps when operating a unit equipped with a lower radiator hose heater 1 Verify the unit is level so as to maintain proper orientation of the heater while it is in operation 2 Verify the cooling system is full of the proper mixture of water and engine coolant before each heater use 3 Use only an undamaged outdoor rated three prong grounded 120VAC extension cord with a minimum amperage r...

Page 30: ...g pins snap into place 3 Use the tongue jack to raise or lower the trailer onto the hitch of the towing vehicle Lock the hitch coupling and attach the safety chains or cables to the vehicle Remove the tongue jack locking pin and rotate the jack into the travel position Replace the locking pin NOTE A film of grease on the coupler will extend coupler life and eliminate squeaking Wipe the coupler cle...

Page 31: ...s 2 Verify the cradle locking pin is in place 3 Close and lock all hoods and doors 4 See Figure 3 11 Stow the mast and lights in the travel position as shown 5 Always remain aware of people and objects around the unit while preparing maneuvering and lifting the unit When lifting the unit attach any slings chains or hooks directly to the central lift point A Use the forklift pockets B with care Lif...

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Page 33: ...rranty Preparing for Service Before servicing the unit always follow the instructions listed below 1 If unit is equipped with the Power Zone controller verify the Control Power switch is OFF Otherwise verify the key switch is in the OFF position 2 Verify the circuit breakers are OFF 3 Disconnect the negative terminal on the battery 4 Activate push in the emergency stop switch 5 Attach a Do Not Sta...

Page 34: ...low the ADD mark on the dipstick Normal operating level is in the cross hatch pattern between the full and add markings on the dipstick Add oil only if the oil level is below the add mark on the bottom of the cross hatch pattern on the dipstick DO NOT OVERFILL the crankcase Check the fuel level If the unit is connected to a remote start or transfer switch verify the remote switch is also off and t...

Page 35: ...y Inspect Radiator Fins For Debris Clean As Required Preheating Condition Check Check Engine Starting Conditions and Noise Conditions Check Exhaust Smoke Condition Inspect Light Tower Winch For Proper Operation Replace Engine Oil Replace Fuel Filter Element Clean Water Sedimenter Element Electromagnetic Pump Filter Replacement or Cleaning Check Fan Belt Tension replace if necessary Oil Filter Elem...

Page 36: ...eck the cable for visible damage every time the winch is operated Examples of damage are cuts knots crushed or frayed portions and broken strands Replace cable immediately if damaged Failure to replace a damaged cable could result in breakage Regularly check the brake for slippage or drift This is detected visually when winch is under load If winch drum continues to turn after controls are release...

Page 37: ...ated with the same lightweight oil For top wind models apply a lightweight oil to the screw stem Figure 4 3 Jack Maintenance Trailer Wheel Bearings The trailer axles are equipped with a grease zerk fitting to allow lubrication of the wheel bearings without the need to disassemble the axle hub To lubricate the axle bearings remove the small rubber plug on the grease cap attach a standard grease gun...

Page 38: ...Maintenance 34 Owner s Manual for MLT4200IVF4 Light Tower This page intentionally left blank ...

Page 39: ...l filter for cracks and abrasion Check for gelled fuel in fuel system in cold weather especially at fuel filter Refer to OEM engine operator s manual for additional information Unit starts but stumbles and dies Ambient temperature too low Intake heater inoperable Check if ambient temperature is within unit limits Check engine air inlet heater functionality High coolant temperature shutdown Low coo...

Page 40: ...e GFCI receptacle Incoming voltage should be 120V 5V If voltage is incorrect the engine speed may need to be adjusted or generator may require service Low transformer output The voltage from the transformer should read approximately 400VAC as the light strikes induces an arc then drop and slowly rise back up to stabilize at 240 260VAC On hard wired models remove the mast junction box cover and ins...

Page 41: ...Wiring Diagrams Owner s Manual for MLT4200IVF4 Light Tower 37 Section 6 Wiring Diagrams Mast Junction Box Wiring and Light Connections 1 3 2 4 2 1 4 3 00175 ...

Page 42: ... BK RD YL TB2 TB1 1 2 3 4 BK RD WT GN RD BK RD BK RELAY 1 RELAY 2 RELAY 3 RELAY 4 BAR TO GND BAR TO GND BAR TO GND BAR TO GND COM NO COIL COIL COM NO COM NO COM NO COIL COIL COIL COIL COIL COIL BK WT BK WT BK WT BK WT YL RD BL BK BK 14AWG BK 14AWG BL 14AWG BL 14AWG RD 14AWG RD 14AWG YL 14AWG YL 14AWG YL RD BL BK TO CNTRL 6 TO CNTRL 7 TO CNTRL 8 TO CNTRL 9 SEE DC DIAGRAM F F N 60HZ 50HZ ON REGULATO...

Page 43: ... 20 AMP G F I RECEPTACLE TO GROUND TO NEUTRAL TO MAIN BREAKER RED BLK BLK RED WHT WHT GRN GRN GRN WHT RED BLK RED RED BLK BLK RED RED RED RED BLK BLK BLK BLK GRN WHT GRN GRN GRN WHT WHT WHT 240 VOLT 50 AMP TWIST LOCK RECEPTACLE RECEPTACLE 240 VOLT 50 AMP TWIST LOCK 30 AMP CIRCUIT BREAKER 30 AMP CIRCUIT BREAKER BREAKER CIRCUIT 50 AMP BREAKER CIRCUIT 50 AMP RED RED 240 VOLT 30 AMP TWIST LOCK RECEPTA...

Page 44: ...CUIT BREAKER 20 AMP G F I OUTLET 20 AMP G F I OUTLET 30 AMP CIRCUIT BREAKER 30 AMP CIRCUIT BREAKER 30 AMP CIRCUIT BREAKER 50 AMP CIRCUIT BREAKER TO GROUND TO NEUTRAL TO MAIN BREAKER RED BLK BLK RED WHT WHT GRN GRN GRN WHT RED BLK RED RED RED RED RED RED RED RED BLK BLK BLK BLK GRN WHT GRN GRN GRN WHT WHT WHT BLK BLK BLK BLK 240 VOLT 50 AMP TWIST LOCK RECEPTACLE 240 VOLT 30 AMP TWIST LOCK RECEPTACL...

Page 45: ...OUTLET 20 AMP G F I OUTLET TO GROUND TO NEUTRAL TO MAIN BREAKER RED BLK BLK RED WHT WHT GRN GRN GRN WHT RED BLK RED RED BLK BLK RED RED RED RED BLK BLK BLK BLK GRN WHT GRN GRN GRN WHT WHT WHT 240 VOLT 30 AMP TWIST LOCK RECEPTACLE BLK BLK RED RED 240 VOLT 30 AMP TWIST LOCK RECEPTACLE 240 VOLT 30 AMP TWIST LOCK RECEPTACLE 240 VOLT 30 AMP TWIST LOCK RECEPTACLE 30 AMP CIRCUIT BREAKER 30 AMP CIRCUIT BR...

Page 46: ... GND BAR BAR TO GND BAR TO GND BAR TO GND TO GND BAR FUEL LEVEL BAR TO GND BK WT VI YL RD WT LOW COOLANT BAR TO GND GY BK OUTPUT H PLUG LOCATION OUTPUT G 10 11 POS PLUG 11 OUTPUT J 13 15 ANALOG INPUT A ANALOG IN COM ANALOG INPUT B 17 18 19 20 CAN H CAN L CAN SCREEN 16 14 LOWER ANALOG INPUT C OUTPUT I 12 PIN LOCATION 10A WT VI WT VI BAR TO GND 2 1 NC E STOP SWITCH RD VI RD VI GY NO 3 4 E STOP SWITC...

Page 47: ...IRE INSERTION END 2 7 5 4 1 3 6 P1 VIEWED FROM WIRE INSERTION END 30 85 86 87A 87 PROX SWITCH 2 WINCH PROX RELAY BK BK YL BL BK WT VI YL DOWN UP CONTACTOR 1 SWITCH 1 BATTERY GN BN BK BK RD BL YL 30 85 86 87A 87 PROX RELAY PROX SWITCH 1 BN UP DOWN BN BK1 BL VI BK BL BN DOWN UP BK2 BK 1 2 6 7 5 3 2 1 5A J1 P1 F1 BK BK BN1 BN2 BL2 BL1 BK BK ...

Page 48: ...TRL PANEL START SOL WIRE TO MAIN BREAKER AUX SWITCH NC PIN TIME DELAY NC COM NO BK SPLICE TIME DELAY NC COM NO BK WT WT VI FLOAT SWITCH LOW FUEL SHUTDOWN B ACC R B C R 1 2 R ACC C B R 1 2 R R B 4 3 2 1 90323_K_06 04 14 LIGHT FUSE 10A 65002 CONNECT TO RED WIRE 10A CIRCUIT BREAKER 90574_ORG_09 12 14 GR YL BL BR 12 VOLT 2 AMP CHARGER RD BK 68118_A_09 12 14 YL GN GY BL RD BK WT RS485 B RS485 A CAN H C...

Page 49: ...MBER TRAILER PLUG RIGHT TAIL TURN LAMP LAMP PLATE LICENSE MARKER LAMP RED BK BK BK BK RD WT BK SPLICE SPLICE SPADE SPADE LAMP TAIL TURN LEFT RD WT BK SPADE YL BN WT SPADE SPADE WT BK BN WT SPLICE GN RING MARKER LAMP AMBER MARKER LAMP RED BK BK BK BK SPLICE SPLICE SPADE SPADE BN WT WT WT BN BN 90341_B_12 20 13 ...

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Page 56: ...ts reserved Specifications are subject to change without notice No reproduction allowed in any form without prior written consent from Generac Mobile Products Generac Mobile Products 215 Power Drive Berlin WI 54923 GeneracMobileProducts com 800 926 9768 920 361 4442 ...

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