Generac Power Systems MAGNUM MLT4250 Owner'S Manual Download Page 5

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Owner’s Manual for MLT Light Tower

Winch Use, Operation and Maintenance .........34

Prior to Use ............................................................... 34
Operation .................................................................. 34
Maintenance ............................................................. 34

Optional Lower Radiator Hose Heater Use and
Maintenance .......................................................34

Trailer Wheel Bearings ......................................34

Jack Maintenance ..............................................35

Section 5:Troubleshooting

General Troubleshooting ..................................37

Troubleshooting the Lights ..............................38

Section 6:Wiring Diagrams

Mast Junction Box Wiring and Light
Connections .......................................................39

AC Wiring Diagram ............................................40

AC Wiring Diagram—Receptacle Panel ...........41

AC Wiring Diagram—Receptacle Panel
Options (1 of 2) ..................................................42

AC Wiring Diagram—Receptacle Panel
Options (2 of 2) ..................................................43

DC Wiring Diagram ............................................44

DC Wiring Diagram—Optional Equipment .....45

Trailer Lights Wiring ..........................................46

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Summary of Contents for MAGNUM MLT4250

Page 1: ...Owner s Manual Light Tower MLT4250 SAVE THIS MANUAL FOR FUTURE REFERENCE www discount equipment com D i s c o u n t E q u i p m e n t c o m ...

Page 2: ...nie Terex JLG MultiQuip Mayco Toro Stone Diamond Products Magnum Airman Mustang Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Brothers Essick Miller Spreader Skyjack Lull Skytrak Tsurumi Husquvarna Target Whiteman Concrete Mortar Stow Concrete Mortar Baldor Wacker Sakai Snorkel Upright Mi T M Sullair Neal Basic Dynapac MBW Weber Bartell Bennar Newman Haulotte Ditch Runner Blaw Kno...

Page 3: ...ll 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 or operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individua...

Page 4: ... Engine Monitoring 16 MDC Fault Reset 17 MDC Operational Status 17 MDC Alarm Management 17 MDC List of Alarms 18 MDC History 19 Adjusting the Backlighting 19 Generator Output Connection Lugs 19 Voltage Selector Switch 20 Emergency Stop Switch 20 Prestart Checklist 21 Starting the Unit Manually 21 Starting the Unit Auto Remote 23 Automatic Shutdown 23 Light Operation 23 Auxiliary Outlets 24 Wet Sta...

Page 5: ...roubleshooting General Troubleshooting 37 Troubleshooting the Lights 38 Section 6 Wiring Diagrams Mast Junction Box Wiring and Light Connections 39 AC Wiring Diagram 40 AC Wiring Diagram Receptacle Panel 41 AC Wiring Diagram Receptacle Panel Options 1 of 2 42 AC Wiring Diagram Receptacle Panel Options 2 of 2 43 DC Wiring Diagram 44 DC Wiring Diagram Optional Equipment 45 Trailer Lights Wiring 46 D...

Page 6: ...ndling all service needs Safety Rules The manufacturer cannot anticipate every possible circumstance that might involve a hazard The warnings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If using a procedure work method or operating technique that the manufacturer does not specifically recommend verify that it is safe for others Also make sure the proce...

Page 7: ...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 000147 WARNING Risk of Fire Unit must be positioned in a manner that prevents combustible material accumulation underneath Failure to do so ...

Page 8: ...on 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 000137a WARNING Explosion Batt...

Page 9: ...ture 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 Explosion and fire Fuel and vapors...

Page 10: ...ns 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 or hold the equipment safel...

Page 11: ...eels and 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 ...

Page 12: ...6 0 Amps 1Ø Standby 240V A 67 1Ø Prime kW kVA 15 0 15 0 Amps 1Ø Prime 240V A 63 Frequency Hz Hertz 60 Power Factor 1 1Ø 0 8 3Ø Sound 23 ft at prime dB A 70 Weights Dry Weight lbs kg 2158 979 Operating Weight lbs kg 2556 1159 Capacities Fuel Tank Volume gal L 56 212 Usable Fuel Volume gal L 56 212 Coolant including engine qt L 11 6 11 0 Oil including filter qt L 8 6 8 1 Maximum Run Time hours 31 AC...

Page 13: ...ight Tower Unit Dimensions Figure 2 1 Unit Dimensions Specifications are subject to change without notice A B C D E MLT4250 170 in 4 32 m 70 in 1 78 m 30 ft 9 14 m 68 in 1 73 m 140 in 3 56 m E C D B A 004647 D i s c o u n t E q u i p m e n t c o m ...

Page 14: ...ESS DE V I N N I V 00000000000000000 TYPE TRAILER MODEL XXX000 GAWR PNBE TIRE PNEU RIM JANTE GONF A FROID KPA PSI LPC SGL DUAL EACH AXLE THIS VEHICLE CONFORMS TO ALL APPLICABLE STANDARDS PRESCRIBED UNDER THE U S FEDERAL MOTOR VEHICLE SAFETY STANDARDS FMVSS AND CANADIAN MOTOR VEHICLE SAFETY REGULATIONS IN EFFECT ON THE DATE OF MANUFACTURE CE VEHICULE EST CONFORME A TOUTES LES NORMES QUI LUI SONT AP...

Page 15: ... A Mast rotation knob E Lower Forklift pockets I Upper forklift pockets B Central lifting point F Battery J Fuel fill C Engine exhaust G Control box K Outriggers D Emergency Stop Switch H Radiator box L Engine access LEFT SIDE RIGHT SIDE 004497 A B C D E F G H J I K L D i s c o u n t E q u i p m e n t c o m ...

Page 16: ...ctor Switch This switch will change the generator output between three phase and single phase power For more information refer to Voltage Selector Switch G Cable Access Allows for entry of load cables to the connection lugs with the lug box door closed H Remote Start Terminal Block Allows connections for remote starting of the unit I Generator Ground Connection Lug This is for connecting a good ea...

Page 17: ...ar the trailer tongue For grounding requirements follow the National Electrical Code NEC state and local regulations 5 Pull the locking pins D on the outriggers E and pull each outrigger out until the spring loaded locking pin snaps back into place Pull the locking pin on each outrigger jack and rotate each jack 90 so the jack pad is facing down and the spring loaded pin snaps back into place 6 Pu...

Page 18: ...scope the mast to the desired height Extend mast slowly verifying the electrical cord is extending at the top sections of the mast Do not extend past the colored mark G IMPORTANT NOTE Contact a Generac Mobile Prod ucts Authorized Service Dealer immediately if the mast hangs up or the winch cable develops slack 7 Rotate mast by loosening mast rotation knob at bottom of mast H Turn mast until the li...

Page 19: ...ow Press this button to scroll down within the LCD window Page Select Pressing this button will select the next display screen Enter Pressing this button will place you inside the particular display to review the unit s preprogrammed setpoints or parameters D Liquid Crystal Display LCD Displays screen upon startup of the unit By viewing these screens the operator will be able to monitor both the e...

Page 20: ...omatically shut down Zero 0 will be displayed until a minimum temperature of 100 F 38 C is reached Vbat Displays the engine battery voltage A normal reading is 13 14V on 12 volt systems and 24 26V on 24 volt systems with the engine running Figure 3 5 Engine Screen Additional information may be viewed while the unit is in Manual or Auto mode By pressing the Page Select button the operator will sele...

Page 21: ... cooling pump output is closed 2 Cooling The unit is cooling before stop 3 Cranking Engine is cranking 4 EmergMan Emergency manual gen set opera tion 5 Init Autotest during controller power on 6 Loaded The unit is running at nominal speed and GCB OPEN CLOSE is closed 7 Not Ready The unit is not ready to start 8 Pause Pause between start attempts 004528 9 Prestart Prestart sequence in process pre s...

Page 22: ...it breaker 13 Igen unbl SD NO The generator current is unbalanced 14 Low BackupBatt WRN NO RTC backup battery is flat low 15 Oil Press Sd SD NO Oil pressure is smaller than Sd Oil Press setpoint 16 Oil Press Wrn WRN YES Oil pressure is smaller than Wrn Oil Press setpoint 17 Overload SD YES The load is greater than the value given by Overload setpoint 18 Overspeed SD YES The protection comes active...

Page 23: ...ue of Volt unbal setpoint 29 Wrn ECU Alarm WRN NO ECU alarm list is not empty Not available on MLG MLT or MTT units 30 Wrn RA15 fail WRN NO Warning alarm in case of lost connection to IGL RA15 mod ule Not available on MLG MLT or MTT units 31 WrnMaintenance WRN NO The period for servicing is set by the WrnMaintenance set point The protection comes active if the running hours of the engine reach thi...

Page 24: ...it breaker which will open the contact disconnecting the load to the connection lugs This will also open the fuel circuit shutting down the engine The switch will remain closed until it is pulled out Figure 3 11 Emergency Stop Switch NOTE Use the emergency stop switch only when the unit must be shut down immediately For any other shut down refer to Shutting Down the Unit 004529 B A VOLTAGES AT REC...

Page 25: ... Check the engine fan belt tension and condition Check the engine fan belt guard Check the engine exhaust system for loose or rusted components Verify all covers are in place and secure Verify all electrical connections at the connection lugs if equipped are tight and wired correctly Verify the voltage selector switch is set to the desired voltage and locked Verify the emergency stop switch is pul...

Page 26: ... 3 17 Generator Engine Display Screens 8 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 LCD window will show PAUSE The engine will make two more attempts to start for a total of three crank cycles 9 Should the engine not start and run within three starting cycles the LCD window will show SD START FAIL The starting...

Page 27: ...two terminals on the remote start terminal block This applies a ground to the Magnum Digital Controller MDC to close the starting circuit contacts The engine should crank start and run d Remove the jumper wire from the remote start terminal block and the engine will stop e Reconnect any necessary wires from the remote start switch transfer switch to the remote start terminal block 3 Confirm unit i...

Page 28: ...tors and buildup on engine valves Diesel engines operate properly when applied loads are between 30 and 100 capacity Appropriate generator sizing is determined by the anticipated load If the unit is in a wet stack condition load the unit heavily for five hours or until the exhaust is clear Voltage Regulator Units are equipped with an electronic voltage regulator The voltage regulator controls the ...

Page 29: ... to the emergency power source generator when normal voltage falls below a prescribed level The transfer switch automatically returns the load back to the normal source when power is restored back to operating levels Figure 3 21 Transfer Switch Operation Installation of a transfer switch or other type of remote starting device is the responsibility of the user Installation of such devices must be ...

Page 30: ... V or Sd Gen L1 V Sd Gen L2 V Sd Gen L3 V This means the controller warned WRN or shutdown SD the unit due to an output voltage irregularity The output voltage of the generator may be adjusted after the unit is running by using the fine voltage adjustment screw A The adjusting screw is located directly below the Control Power switch on the control panel This screw turns a rheostat that will provid...

Page 31: ... pull free activate the lower winch slightly to relieve pressure on the mast bar 5 After the mast is completely down insert the mast cradle locking pin and secure it with the safety pin NOTE Generac Mobile Products strongly recommends that the lights be removed from the mast and stowed for transportation See Removing the Lights for Transportation Removing the Lights for Transportation 1 See Figure...

Page 32: ... enclosure is properly latched and the mast cradle lock is in place 7 Verify the doors are properly latched and the mast pin is in place 8 If driving over rough ground remove the bulbs from the light fixtures 9 Check for proper inflation of the trailer tires For maximum tire pressures refer to Specifications 10 See Figure 3 25 Check the wheel lugs Tighten or replace any lugs that are loose or miss...

Page 33: ...r s Manual for MLT Light Tower 29 sure the mast winch handles or any other obstructions are clear of the forklift tines before lifting Figure 3 26 Lifting Point 004666 B A C C D i s c o u n t E q u i p m e n t c o m ...

Page 34: ...w 1 Verify the Control Power switch is in the OFF O position 2 Verify the circuit breakers are switched OFF O 3 Activate push in the Emergency Stop Switch 4 Disconnect the negative terminal on the battery 5 Attach a Do Not Start sign to the control panel This will notify everyone that the unit is being serviced and will reduce the chance of someone inadvertently trying to start the unit Cleaning t...

Page 35: ...d 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 make sure the remote switch is also off and tagged NOTE If the engine was run out of fuel or the fuel tank was drained it may be necessary to bleed the fuel lines Refer to the engi...

Page 36: ...lay screen The current service time hour setting 0 will be one line below it on the right side 6 Press ENTER The current run time in hours will now appear on the left side of the display screen directly under WrnMaintenance 7 Press and reset the current run time hour setting to 250 If you pass the 250 time interval use to get back to the 250 time interval Table 4 1 Basic Maintenance Guide Isuzu It...

Page 37: ...ushings as needed C 2 The ratchet pawl pivot point must be kept lubricated with a thin oil NOTE Do not get oil or grease on the friction discs A Figure 4 3 Winch Maintenance Optional Lower Radiator Hose Heater Use and Maintenance The following points should be followed when operating a unit equipped with a lower radiator hose heater IMPORTANT NOTE Improper use of the lower radiator hose heater cou...

Page 38: ...nd bushings of the jack must be kept lubricated See Figure 4 4 Apply a small amount of automotive grease A to the internal gearing by removing the jack cover or if equipped use a needle nose applicator or standard grease gun on the lubrication point found on the side of the jack near the crank Rotate the jack handle to distribute the grease evenly A lightweight oil B must be applied to the handle ...

Page 39: ...temperature shutdown Low coolant level Add coolant if needed Allow engine to cool then check coolant level in radiator Restart engine and check coolant temperature Stop engine immediately if coolant temperature is 210 F 99 C or more Blockage in radiator Inspect radiator shroud and ducting for blockage and remove any foreign matter Leakage in coolant hoses engine block or water pump Inspect for vis...

Page 40: ...ing the available voltage on the 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 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...

Page 41: ...Wiring Diagrams Owner s Manual for MLT Light Tower 39 Section 6 Wiring Diagrams Mast Junction Box Wiring and Light Connections 00768 1 3 2 4 D i s c o u n t E q u i p m e n t c o m ...

Page 42: ...2 3 1 4 2 3 1 4 2 5K 2 WATT ADJUSTMENT VOLTAGE 13 14 1 2 3 4 R1 R2 R3 R4 XFMR 1 XFMR 2 XFMR 3 XFMR 4 CAP3 CAP4 CAP1 CAP2 RD1 RD2 RD3 RD4 BK4 BK3 BK2 BK1 T7 T9 L1 L2 L3 N GND RD BK WT GN SPLICE SPLICE WT WT BK BK BK BK 120V 120V 120V 120V 120V 120V WT WT BN WT WT WT BK BL RD YL 120V 120V CAP CAP CAP CAP COM COM COM COM RD GY GY RD BL BL BK BK BK BL RD YL BN WT GN TO RECEPTACLE PANEL PUMP ONLY MTT 1...

Page 43: ...ACLE 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 RECEPTACLE 90317_ORG_07 06 ...

Page 44: ...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 RECEPTACLE 240 VOLT 30 AMP TW...

Page 45: ...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 BREAKER 30 AMP CIRCUIT...

Page 46: ...VIO GN YL VI YL FUEL PUMP WT BL WT YL BK YL RD WT BK WT RD YL RD YL RED RED RD WT RD WT VI YL ORN VI YL BLK ORN BLK YEL BLU RED RED RED RD WT RD WT RED RED BLK BLUE 10GA BLUE 10GA BK YL COMMUNICATION MODULE TAIL LIGHT HARNESS BRN WHT TO SHUNT TRIP COMMON RD WT 65567 1 65568 2 65568 1 65569 1 66207 1 65571 1 4 3 2 1 4 3 2 1 7 6 5 4 3 2 1 1 2 3 1 2 3 1 2 GND 15A 87 NO 30 COM 85 86 GLOW PLUGS 4 3 2 1...

Page 47: ...D VI TO GND BAR 25A RD BK 10A MTB PIN 12 ALT CONFIG POSITIVE AIR SHUTDOWN 6 20KW BK WT RPM SENSOR PASS GND PWR RPM SW OPT GND SOL CIRCUIT BREAKER 20A BATTERY 12 V ESTOP SOLENOID PASS RD WT BK SPLICE SPLICE RD RD WT BK WT1 PNK BK1 BK BK WT BK WT2 GY TO GND BAR TO GND BAR OR YL1 OR YL2 TO CNTRL PANEL START SOL WIRE TO MAIN BREAKER AUX SWITCH NC PIN TIME DELAY NC COM NO BK SPLICE TIME DELAY NC COM NO...

Page 48: ...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 D i s c o u n t E q u i p m e n t c o m ...

Page 49: ...le Products All rights reserved Specifications are subject to change without notice No reproduction allowed in any form without prior written consent from Generac Mobile Products www discount equipment com D i s c o u n t E q u i p m e n t c o m ...

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