Generac Power Systems MLT4200IF4 Owner'S Manual Download Page 5

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Table of Contents

Owner’s Manual for MLT4200IF4 Light Tower

Jack Maintenance ..............................................36

Trailer Wheel Bearings ......................................36

Section 5: Troubleshooting

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

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

Section 6: Wiring Diagrams

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

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

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

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

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

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

DC Wiring for Optional Equipment ..................45

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

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Summary of Contents for MLT4200IF4

Page 1: ...Owner s Manual Light Tower MLT4200IF4 SAVE THIS MANUAL FOR FUTURE REFERENCE 003975 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 2: ... ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wisconsin Northrock Oztec Toker TK Rol Air APT Wylie Ingersoll Rand Doosan Innovatech Con X Ammann Mecalac Makinex Smith Surface Prep Small Line Wanco Yanmar Discount Equipment com is your online resource for commercial and industrial qu...

Page 3: ... 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 the warranty Individual ope...

Page 4: ...art Checklist 22 Raising the Mast 23 Preparing for Start Up 24 Select AUTO or MANUAL Mode 24 Configure for Intended Use 24 Emergency Stop Switch 24 Engine Break In Requirements 24 Manually Starting the Unit 25 Auto Remote Starting of the Unit 25 Light Operation 25 Engine Derating 26 Wet Stacking 26 Voltage Regulation 26 Customer Convenience Outlets 26 Remote Start Terminal Block 27 Transfer Switch...

Page 5: ...eshooting the Lights 38 Section 6 Wiring Diagrams Mast Junction Box Wiring and Light Connections 39 AC Wiring 40 AC Wiring Receptacle Panel 41 AC Wiring Receptacle Panel Options 1 of 2 42 AC Wiring Receptacle Panel Options 2 of 2 43 DC Wiring 44 DC Wiring for Optional Equipment 45 Trailer Lights Wiring 46 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 6: ...ght 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 procedure work method or operating technique utilized does not render the equipment unsafe Throughout this public...

Page 7: ... 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 000147 WARNING Risk of Fire Unit ...

Page 8: ...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 Batteri...

Page 9: ... 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 are...

Page 10: ...nd 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 safely Al...

Page 11: ...ear 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 terrain When towing maintain extra sp...

Page 12: ...re Tilting Mast Down 10 Danger Secure Mast 11 Grounding Stud 12 Receptacle Panel Circuit Breaker Locations 13 Warning Crushing Hazard 14 Warning Ultraviolet Radiation 15 Warning High Winds and Electrical Storms 16 Instructions Set Up 17 Instructions Starting and Stopping the Generator 18 Warning Moving Parts and Hot Surface 19 Consult Manual 20 Instruction Disconnect Battery Before Servicing 21 Re...

Page 13: ...rages electriques DO NOT set up unit in winds exceeding 60 mph or during electrical storms ELECTRICAL STORMS HIGH WIND WARNING WARNUNG ADVERTENCIA ADVERTISSEMENT 60 mph ADVERTENCIA WARNUNG WARNING Ultraviolet radiation from lamp can cause serious skin and eye irritation Use only with provided undamaged lens cover and fixture AVERTISSEMENT Die ultraviolette Strahlung der Lampe kann zu schwerer Haut...

Page 14: ...sleitungen kann zu schweren oder lebensgefährlichen Verletzungen führen Den Beleuchtungswagen nie direkt unter Hochspannungsleitungen aufstellen El contacto con las líneas electricas elevadas podría causar lesiones serias o la muerte No posicione la torre de iluminación debajo de líneas electricas Le contact avec des câbles électriques suspendus causera des blessures graves ou la mort Ne pas posit...

Page 15: ...HVR EUXWR GHO YHKtFXOR GHO UHPROTXH QJDQFKH ILUPHPHQWH HO UHPROTXH DO YHKtFXOR GH UHPROTXH QJDQFKH ODV FDGHQDV GH VHJXULGDG HQ IRUPD FUX DGD QJDQFKH DO YHKtFXOR OD FDGHQD GH HPHUJHQFLD SDUD DYHUtDV 5HYLVH ODV OXFHV GHO UHPROTXH ABSCHLEPPANWEISUNGEN LUH OH PDQXHO GH O XWLOLVDWHXU 8WLOLVHU XQ DWWHODJH FRQYHQDQW DX SRLGV QRPLQDO EUXW GH OD UHPRUTXH UULPHU VROLGHPHQW OD UHPRUTXH DX YpKLFXOH WUDFWHXU 3...

Page 16: ...e 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 2105 955 Operating Weight lbs kg 2395 1086 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 Circuit Breaker Size amperes 100...

Page 17: ...er Unit Dimensions Figure 2 1 Unit Dimensions Specifications are subject to change without notice A B C D E MLT4200IF4 115 in 2 92 m 70 in 1 78 m 30 ft 9 14 m 68 in 1 73 m 140 in 3 56 m 003976 A B C D E T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 18: ...sidiary of Generac Power Systems Inc 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 DATE 00 0000 GVWR PNBV 000KG 0000LBS COLD INF PRESS PRESS DE V I N N I V 00000000000000000 TYPE TRAILER MODEL XXX000 GAWR PN...

Page 19: ...ift Point H Leveling Jack B Mast Rotation Knob I Radiator Access C Emergency Stop Switch J Grounding Stud D Control Panel Access K Receptacle Panel E Tongue Jack L Fork Lift Pockets F Engine Access M Engine Access G Fuel Fill Access 003978 A B C D E F G H I J K H L M T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 20: ...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 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 21: ...lays 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 and the engine is in ready to ...

Page 22: ... 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 running OIL Displays engine oil p...

Page 23: ...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 the generator system They serve...

Page 24: ...nce 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 Figure 2 14 Event Log Screen To vi...

Page 25: ...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 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 26: ...n 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 Reinstall the locking pin 6 Pull the locking pin on the rear jack F and rotate the jack 90 Reinstall the locking pin Rotate the jack handle clockwise to start leveling the trailer see Detail G Adjus...

Page 27: ...General Maintenance Verify battery connections are secure Turn the battery disconnect switch ON if equipped 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 Raising the Mast 1 Set up and level the unit See Light Tower Setup Figure 3 2 Pulley Locations 000100a WARN...

Page 28: ...ANUAL on the Home screen AUTO mode is required for programming automatic start and stop times see Scheduler Screen or enabling the Night Watchman sensor see Scheduler Screen MANUAL mode is used for on demand control of the lights and convenience outlets Figure 3 3 Selecting MANUAL or AUTO Mode Configure for Intended Use As described in General Information the engine in this unit runs at low speed ...

Page 29: ... ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wisconsin Northrock Oztec Toker TK Rol Air APT Wylie Ingersoll Rand Doosan Innovatech Con X Ammann Mecalac Makinex Smith Surface Prep Small Line Wanco Yanmar Discount Equipment com is your online resource for commercial and industrial qu...

Page 30: ... more information on regular maintenance intervals refer to Basic Maintenance Guide Manually Starting the Unit STOP mode is the default start up setting for all units equipped with the Power Zone DLA Use the following procedure to start the generator in MANUAL mode 1 Verify the 240VAC outlet breaker is switched OFF O 2 Switch the main circuit breaker ON I 3 When the controller powers up the Home s...

Page 31: ...the main circuit breaker ON I 2 To turn the light s ON press the Select button To turn the light s OFF press the Select button Figure 3 5 Lights Screen NOTE The lights require a warm up period of 5 15 minutes before they reach full output If the lights are shut down they require a cool down period of approximately 10 minutes before they can be switched on again NOTE The light tower uses four 1000W...

Page 32: ...se appliances do not have grounded plugs a ground wire MUST be added between the equipment and the grounding stud on the receptacle panel per the National Electrical Code NEC state and local regulations Remote Start Terminal Block See Figure 3 7 The remote start terminal block A is located near the control panel and provides a connection for installation of a remote start switch which will allow t...

Page 33: ...er number to adjust the time of the desired event and then press the AUTO button to enter it Press the MANUAL START I and 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 butt...

Page 34: ...day 910 Scheduler 2 Start Week 1 2 3 4 911 Scheduler 2 Duration 0 00 00 912 Scheduler 3 Start Time 0 00 00 913 Scheduler 3 Start Day 0 1 Monday 914 Scheduler 3 Start Week 1 2 3 4 915 Scheduler 3 Duration 0 00 00 916 Scheduler 4 Start Time 0 00 00 917 Scheduler 4 Start Day 0 1 Monday 918 Scheduler 4 Start Week 1 2 3 4 919 Scheduler 4 Duration 0 00 00 920 Scheduler 5 Start Time 0 00 00 921 Scheduler...

Page 35: ...er is designed to be operated overnight if necessary two to five hours of heating just prior to starting is usually sufficient for proper engine starting NOTE Use the lower radiator hose heater only in its designated location Improper use can damage the engine Perform the following steps when operating a unit equipped with a lower radiator hose heater 1 Verify the unit is level so as to maintain p...

Page 36: ...llow these steps to prepare the unit for towing 1 Raise the rear jack completely and release the locking pin to rotate it up into the travel position Verify the locking pin snaps into place 2 Raise the outrigger jacks completely and release the locking pins to rotate them up into the travel position Verify the locking pins snap into place Release the outrigger locking pins and slide the outriggers...

Page 37: ...ent being used to lift the unit is in good condition and has sufficient capacity For approximate weights refer to Specifications 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 l...

Page 38: ...Operation 32 Owner s Manual for MLT4200IF4 Light Tower This page intentionally left blank T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 39: ...one 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 Start sign to the control panel This will notify everyone that the unit is being serviced and will reduce the chance of someone inadvertentl...

Page 40: ...manual supplied with the unit Basic Maintenance Schedule Refer to the original equipment manufacturer s operating manual for a complete list of maintenance requirements Failure to comply with the procedures as described in the engine operator s manual will nullify the warranty decrease performance and cause equipment damage or premature equipment failure Maintenance records may be required to comp...

Page 41: ...replace if damaged Check mounting hardware and tighten if necessary Gears ratchet pivot point and shaft bushings must be kept lubricated with a thin film of oil or grease Operation Raising the Lights 1 The cable must be securely fastened to the object being lifted and to the winch drum 2 Verify the cable and cable attachments are not damaged Contact Generac Mobile Products to order a replacement c...

Page 42: ...oil For top wind models apply a lightweight oil to the screw stem Figure 4 4 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 fitting to the grease zerk fit...

Page 43: ...eck 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 coolant level Blockage in radiator Deb...

Page 44: ...age 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 insert the wire probes into the co...

Page 45: ...iagrams Owner s Manual for MLT4200IF4 Light Tower 39 Section 6 Wiring Diagrams Mast Junction Box Wiring and Light Connections 1 3 2 4 2 1 4 3 00175 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 46: ...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 REGULATOR 4 AMP FUSE F F 3 4 6 7 SE350 V...

Page 47: ...UND 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 11 T o o r ...

Page 48: ... 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 TWIST LOCK REC...

Page 49: ...ROUND 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 BREAKER 30...

Page 50: ...AR 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 SWITCH BK WT BAR TO GND RD YL RD RELA...

Page 51: ...KW 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 BK WT WT VI FLOAT SWITCH LOW FUEL SHUTDOWN B ACC R B C R 1 2 R ACC C B R 1 2 ...

Page 52: ...RN 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 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 53: ..._______________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ _________________________...

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Page 57: ...T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 58: ...obile 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 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 59: ... ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wisconsin Northrock Oztec Toker TK Rol Air APT Wylie Ingersoll Rand Doosan Innovatech Con X Ammann Mecalac Makinex Smith Surface Prep Small Line Wanco Yanmar Discount Equipment com is your online resource for commercial and industrial qu...

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Generac Power Systems MLT4200IF4, Owner'S Manual, Page: 5 / 59

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