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Generac Power Systems MLT6SMD, Owner'S Manual

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Generac Power Systems MLT6SMD Owner'S Manual Download Page 51

Wiring Diagrams

Owner’s Manual for MLT6SMD Light Tower

47

DC Wiring

FA

N

30

87

86

85

RD

BK

INT

AKE HEA

T

ER

RD

PHOTO SENSOR

BK

YL

RD

NIGHT WATCHMAN

1

2

3

4

5

6

7

8

9

10

11

12

(GRA

Y

 )

30

87

86

85

30

87

86

85

RD

BK

BK

GLOW PLUGS

RD

BK

10

10

10

10

VI/YL

16

RD

BK/YL

16

FUSE LINK

VI/YL

16

GY/RD

16

BK/WT

16

WT/BK

16

10

14

SPADE

BL

FUSE LINK

14

10

SPLICE

SPLICE

ENGINE COOLANT

TWO SPEED

SWITCH

15A

15A

25A

20A

30

87

86

85

30

87

86

85

30

87

86

85

30

87

86

85

SPLICE

RD

RD

RD

RD/YL

RD

GY/YL

VI/YL

HEA

T

ED

FUEL

 FIL

T

ER

GY/RD

16

GY/RD

16

RD

10

GY/RD

16

GY/RD

16

RD

10

BK/VI

SPLICE

SPLICE

RD

BK

FUEL

PUMP

VI/YL

BK/WT

BLK

A

T

MOSPHERIC

SENSOR

Vo

u

t

GND

Va

c

BK

GY

RD

MAG

PICKUP

VI/YL

GN

BK/WT

BK

BK/VI

OR/YL

DC POS SUPPL

Y

N/C

GND FOR 

AUX INPUTS

N/C

DC NEG SUPPL

Y

N/C

PWR FOR PRES SENSOR

INPUT

 FOR 

ACC POS SENSOR

N/C

INPUT

 FOR 

A

T

MOS SENSOR

N/C

12

11

10

9

8

7

6

5

4

2

1

3

SPEED SIG INPUT

BK/VI

ELECTRONIC

GOVERNOR

3

4

1

2

OR/YL

OR/BK

GY

OR/YL

1.0K

3.83K

1.1K

12V BA

TTER

Y

1

2

3

4

5

6

7

8

9

10

11

12

RD/WT

OR/WHT

YL

WT/BL

BK/YL

WT/YL

RD/VI

ENGINE CONNECT

OR

(GREEN )

TEMP

COOLANT

SWITCH

BK/WT

GY/YL

SPLICE

RD

AL

TERNA

T

OR

ST

AR

TER

RD

RD/YL

OIL

 PRESSURE

W

A

RNING SW

(N.C.)

SPLICE

SPLICE

SP

ADE

CONTROL

LIGHTS

TRAILER

SPADE

SPADE

BK/WT

16

16

16

16

12

16

12

14

14

RD/WT

16

BK

6

RD/YL

16

VI/YL

16

16

16

VI/YL

VI/YL

16

RD

12

BK

12

16

16

16

16

16

16

16

16

GY

16

BK

GY

GN

BK

16

BK/VI

16

VI/YL

16

VI/YL

16

VI/YL

16

VI/YL

16

VI/YL

16

VI/YL

16

VI/YL

16

VI/YL

16

VI/YL

16

16

BK

6

YL

RD/VI

OR/WT

OR/WT

RD

FUSE LINK

14

FUSE LINK

14

BK/YL

16

WT/BL

VI

YL/GN

BK/WT

BN

18

BK/VI

18

A

B

A

B

F

A

N CONNECTION

10

JUMPER CABLE

A

B

C

1

2

SPEED VOL

T

A

GE REFERENCE

ELECTRONIC

GOVERNOR

3.83K

1.0K

1.1K

INPUT

 FOR 

ACC POS SENSOR

87A

OR/YL

16

OR/BLK

16

75013B_H_09.08.16

Summary of Contents for MLT6SMD

Page 1: ...Owner s Manual Light Tower MLT6SMD S N 3002908801 and above SAVE THIS MANUAL FOR FUTURE REFERENCE For technical assistance contact www generacmobileproducts com Technical Support 1 800 926 9768 ...

Page 2: ...o have the equipment checked periodically by a GMP ASD 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 operating habits and usage may contribute to the need for additional maintenance or service Unit Model Number Unit Serial Number Engine M...

Page 3: ...ed Engine 21 PowerZone DLA 22 Controller Features and Functions 22 Operator Screens 23 Section 3 Operation Light Tower Setup 29 Prestart Checklist 30 Raising the Mast Manual Winch 30 Raising the Mast Electric Winch If Equipped 31 Preparing for Start Up 32 Select Auto Mode or Manual Mode 32 Configure for Intended Use 32 Manually Starting the Unit 32 Light Operation 33 Engine Derating 33 Wet Stackin...

Page 4: ...e 41 Winch Use Operation and Maintenance Electric 41 Winch Mechanical Brake 42 Trailer Wheel Bearings 42 Jack Maintenance 42 Section 5 Troubleshooting General Troubleshooting 43 Section 6 Wiring Diagrams AC Wiring 45 DC Wiring Control Box 46 DC Wiring 47 DC Wiring Electric Winch Option 48 Trailer Wiring 49 Section 7 Service Log ...

Page 5: ...ork method or oper ating technique that the manufacturer does not specifically recommend verify that it is safe for others and does not render the equipment unsafe Throughout this publication and on tags and decals affixed to the unit DANGER WARNING CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectl...

Page 6: ...or corrosion Doing so could result in death serious injury or property damage 000349 WARNING Personal Injury Do not use lifting hook other than as directed Failure to do so could result in death serious injury or property damage 000350 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 ...

Page 7: ...188 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 000137a ...

Page 8: ...mmable and explosive Keep fire and spark away Failure to do so will result in death or serious injury 000174 DANGER Risk of fire Allow fuel spills to completely dry before starting engine Failure to do so will 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 t...

Page 9: ...AUTION 000291 Equipment damage Do not attempt to start or operate a unit in need of repair or scheduled maintenance Doing so could result in serious injury death or equipment failure or damage WARNING 000277 WARNING Burn hazard Never operate lights with a damaged or missing lens cover Lamps are hot and pressurized while in use Unprotected lamps can shatter causing severe injury WARNING Electrocuti...

Page 10: ...spect the hitch and coupling for wear or damage Before towing the trailer verify the weight of the trailer is equal across all tires On trailers with adjustable height hitches adjust the angle of the trailer tongue to keep the trailer as level as possible Running Lights Verify directional and brake lights on the trailer are con nected and working correctly Wheels and Tires Inspect trailer tires fo...

Page 11: ...laints it may open an investigation and if it determines a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in an individual problem between you your dealer or Gen erac Mobile Products LLC To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www safercar gov o...

Page 12: ...t Outriggers With Tower Up 15 Warning Electrical Storms and High Wind 3 Notice Avoid Tangling Winch Cable 16 Danger Do Not Operate Beneath Electrical Wires In Electrical Storms or In High Winds Read Owner s Manual Do Not Tow With Mast Raised 4 Electric Shock Hazard 17 Warning Hot Surface 5 Lifting Point 18 Warning Pressurized Liquid 6 Forklift and Tie Down Point 19 Disconnect Battery Before Servic...

Page 13: ...216 16758 21 6 3 5 5 02 48 HD HO PDQXDO GHO RSHUDGRU 8VH XQ HQJDQFKH DGHFXDGR SDUD OD FDSDFLGDG GH SHVR 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 6 33 1 681 1 LUH OH PDQXHO GH O XWLOLVDWHXU 8WLOLVHU XQ DWWHODJH FRQYHQD...

Page 14: ... 15 16 21 17 23 Nicht bei Windgeschwindigkeit von mehr als 95 km h oder bei Gewitter aufstellen No instalar cuando el viento exceda los 95 km h o durante tormentas eléctricas Ne pas installer dans des vents excédant 60 mph ou pendant les orages electriques DO NOT set up unit in winds exceeding 60 mph or during electrical storms ELECTRICAL STORMS HIGH WIND 60 mph WARNING 24 NEUTRAL BONDED TO FRAME ...

Page 15: ...Introduction and Safety Owner s Manual for MLT6SMD Light Tower 11 Figure 1 3 Decal Locations 3 of 3 25 12 12 006433 ...

Page 16: ...Introduction and Safety 12 Owner s Manual for MLT6SMD Light Tower This page intentionally left blank ...

Page 17: ...ry Voltage quantity per unit 12 1 Battery Rating cold cranking amps CCA 440 Generator Make Marathon Model 331CSA3018 Type Insulation Brushless F Generator Set Engine Generator Output Standby kW kVA 6 0 6 0 Output Voltage volts 120 240 single phase Output Amperes 120V 240V amperes 20 25 Frequency Hz Hertz 60 Power Factor percentage 1 1Ø CSA Listed Yes Weights Dry Weight lbs kg 1332 604 Operating We...

Page 18: ...ated on top of control box Serial Number V A Model KVA Manufacturing Code 1 ph 1 0PF 3 ph 8PF 3 ph 1 0PF KW Country of Origin Weight lbs kg RPM Frequency Rating Ins Class FOR ELECTRICAL EQUIPMENT ONLY POUR MATERIAL ELECTRIQUE SEULEMENT 209649 Form SFC626B Manufactured by Generac Mobile Products LLC 920 361 4442 800 926 9768 TIRE AND LOADING INFORMATION RENSEIGNEMENTS SUR LES PNEUS ET LE CHARGEMENT...

Page 19: ...emove jack from tongue weldment Hold jack vertically and extend until weldment on jack is aligned with tongue weldment 4 See Figure 2 3 Install jack and secure with clevis D Figure 2 3 Jack Installed 5 See Figure 2 2 Remove pins B and C 6 See Figure 2 4 Using both hands slowly lower trailer tongue into tow position NOTE Varying levels of effort may be required depending on terrain Figure 2 4 Lower...

Page 20: ...levels of effort may be required depending on terrain Figure 2 7 Pivot Trailer Tongue Into Storage Position 5 See Figure 2 8 Install pins B and C at locations shown to secure trailer tongue in storage position Figure 2 8 Install Pins and Rotate Jack 6 Remove clevis and remove jack A from tongue weldment 7 Completely retract jack 8 Rotate jack 90 counterclockwise place jack on tongue weldment and i...

Page 21: ... s Manual for MLT6SMD Light Tower 17 Unit Dimensions Figure 2 9 Unit Dimensions Specifications are subject to change without notice A B C D E MLT6SMD 118 in 3 m 101 in 2 6 m 23 ft 7 m 57 in 1 5 m 120 5 in 3 1 m D E C A B 006435 ...

Page 22: ...Locations Figure 2 10 Component Locations Front and Left Side A Grounding studs Interior On enclosure floor behind controller Exterior On bumper E Tongue jack B Outrigger and jack F Mast rotation knob C Fuel fill G Winch D Tie down location H Light 006436 B F D D G H A E C ...

Page 23: ...MD Light Tower 19 Figure 2 11 Component Locations Rear and Right Side 006437 J P N M K L J Central lift point M Tandem tow mount optional not shown K Engine radiator access hood N Hood latch L Forklift pocket P Control panel J Central lift point ...

Page 24: ... MLT6SMD Light Tower Control Panel Figure 2 4 Control Panel 002986 120VAC OUTLET BREAKER DC CIRCUIT BREAKER CONTROL POWER 240VAC OUTLET BREAKER MAST LIGHT CIRCUIT BREAKERS MAST CIRCUIT BREAKER MAST UP MAST DOWN LOAD SENSE A B C D L K J H G E F ...

Page 25: ...d according to lighting and export power requirements The 240VAC 30A main breaker H must be ON to enable Automatic Load Sense Turning Automatic Load Sense switch ON enables Automatic Load Sense the default setting for normal export power operation Turning Automatic Load Sense switch OFF disables Automatic Load Sense and allows the engine to run at high speed when the 240VAC 30A main breaker H is O...

Page 26: ...Window Displays the various operating screens The operator can monitor both the engine and generator status while the unit is running by viewing these screens B Select LED Illuminates when the unit is running in Auto mode C Start LED Illuminates when the unit is running in Manual mode D Start Button Starts the engine if there are no shutdown errors and the engine is in ready to start status E Stop...

Page 27: ...powered up and the unit management software is loaded Displays the controller mode total operating hours hours left until the next service interval engine operating status and engine rpm If the unit is in Auto mode the Home screen may also display whether the scheduler or dusk to dawn are enabled Figure 2 7 Home Screen Battery Voltage Screen See Figure 2 8 Displays the engine battery voltage A nor...

Page 28: ...Dusk to Dawn Screen NOTE This feature will only work in Auto mode See Figure 2 12 Enables or disables the dusk to dawn function which uses a photo sensor to detect the surrounding light level automatically starting the engine and turning the lights on at dusk The engine will run and the lights will remain illuminated until dawn For instructions on using the Dusk to Dawn feature see Dusk to Dawn Se...

Page 29: ...agnostic 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 16 Alarms Screen Warnings are non critical alarm conditions and do not affect the operation of the generator system They serve to draw the operator s attention to an undesirable condition By default warning alarms...

Page 30: ...lays 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 The log always contains the most recent shutdown alarms Figure 2 18 Event Log Screen To view the event log 1 Press the and buttons simultaneously to display the navigation men...

Page 31: ... Figure 2 19 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 19 About Screen 08 27 2015 04 22PM Product L401MKII A4 U ID 21CFB579D S B 01970 ...

Page 32: ...General Information 28 Owner s Manual for MLT6SMD Light Tower This page intentionally left blank ...

Page 33: ...National Electrical Code NEC guidelines 5 See Details C D Pull the locking pins C on the outriggers D 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 See Detail E Rotate each jack handle clockwise to start leveling the trailer Adjust all ...

Page 34: ...ions are secure Turn the battery disconnect switch on if equipped Inspect the engine fan belt tension and condition Inspect the engine fan belt guard Inspect the engine exhaust system for loose or rusted components Verify all covers are in place and secure Raising the Mast Manual Winch 1 Set up and level the unit See Light Tower Setup 2 See Figure 3 2 Inspect the mast cables for exces sive wear or...

Page 35: ... the mast rotation knob to secure the mast in position 4 Press and hold the winch control switch Detail B upward to telescope the mast to the desired height Verify that the coiled electrical cord is extending at the top sections of the mast STOP extending the mast when the colored mark C on the second mast section is visible as seen in Detail C IMPORTANT NOTE A limit switch on the main mast sectio...

Page 36: ...ecting applied load s such as hand tools and low amperage equipment Table 3 1 illustrates the four possible combinations of 240VAC 30A main breaker and load sense switch posi tions Manually Starting the Unit Stop mode is the default start up setting for all units equipped with the Power Zone DLA Proceed as follows to start the generator in Manual mode 1 Verify the 240VAC 30A main breaker is OFF O ...

Page 37: ...ht Operation See Figure 3 5 The lights are turned on and off using the Power Zone DLA To view the light screen press the button three times from the Home screen NOTE The lights can only be turned on and off while the unit is running in Manual mode They operate automati cally in Auto mode 1 Switch the main circuit breaker to ON I when the engine is up to temperature and running smoothly 2 To turn t...

Page 38: ...y the unit and notify them power will be turned off Verify the power shutdown will not create any hazards by accidentally turning off equip ment that needs to remain running pumps compres sors lights etc 1 Remove all loads from the receptacles 2 Switch the lights off using the controller 3 Set the outlet breaker to OFF O 4 Press the Stop O button 5 Set the control power switch to OFF O after the u...

Page 39: ...ment status information to the user via cellular or satellite connection Spark Arrester If Equipped A spark arrester installed on the unit exhaust may be required by code in certain municipalities Contact the local authority having jurisdiction to determine whether or not a spark arrester must be installed on the unit before operation Lowering the Mast Manual Winch 1 Shut down the lights and engin...

Page 40: ...s to prepare the unit for towing 1 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 into the trailer frame until the locking pins snap into place 2 Use the tongue jack to raise or lower the trailer onto the hitch of the towing vehicle Lock ...

Page 41: ...ts in the travel position as shown 4 Always remain aware of people and objects around the unit while preparing maneuvering and lifting the unit Before lifting the unit attach any slings chains or hooks directly to the central lift point A Figure 3 11 Lifting Points Use the forklift pockets B with care Lift only from the side or the rear Avoid approaching the unit at an angle as this can permanentl...

Page 42: ...Operation 38 Owner s Manual for MLT6SMD Light Tower This page intentionally left blank ...

Page 43: ...eing serviced and reduce the chance of unwanted operation Cleaning the Unit Always clean the unit after each use to remove dust grease mud or spilled fuel or oil Use soft clean rags to wipe the cabinet exterior and control panel Low pressure compressed air less than 40 psi 276 kPa can also be used to remove dust and debris from the cabinet interior This unit contains sensitive electronic component...

Page 44: ... operator s manual contact a GMP ASD Perform after the initial 50 hours of operation ONLY then on the regularly scheduled interval as indicated in the table above Generac Mobile Products LLC recommends that oil change intervals on the MLT6SM equipped with the Mitsubishi L3E W461ML Tier 4 engine be extended to 750 hours after initial break in if operating at high speed The engine comes from the fac...

Page 45: ...n to lift The ratchet MUST make a loud clicking sound while winding the cable Lowering the Lights Referring to the Lift Let Down decal on the winch turn handle according to the specified direction to lower No clicking will be heard because the brake system is acti vated Maintenance The following procedures should be performed at least annually 1 The gears and bushings of the winch must be kept lub...

Page 46: ...2 Wheel Bearing Cross Section 2 Attach a standard grease gun fitting to the Zerk grease fitting C 3 Pump grease into the Zerk fitting until fresh grease is visible around the nozzle of the grease gun 4 Wipe any excess grease from the axle hub with a clean cloth and install the rubber plug The minimum recommended lubrication is every 12 months or 12 000 mi 19 312 km More frequent lubrication may be...

Page 47: ... knowledge or skills should be referred to a GMP ASD 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 000187 WARNING Electrocution Potentially lethal voltages are generated by this equipment Render the equipment safe before attempting repairs or maintenance Failure to do so could result in death or serious inj...

Page 48: ...re shutdown Low coolant level Allow engine to cool then check coolant level in radiator Add coolant if needed Blockage in radiator Inspect radiator surroundings for blockage and remove any foreign matter Debris on radiator face Broken coolant pump belt Inspect for visible leaks Check tension of water pump drive belt Cooling fan inoperable Remove load on generator and restart engine Check coolant t...

Page 49: ...Wiring Diagrams Owner s Manual for MLT6SMD Light Tower 45 Section 6 Wiring Diagrams AC Wiring 75022 ...

Page 50: ...NPUT 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 RD VI RD YL BK BL RD OR WT YL BK OR WT BK WT WT CT 1 BK BAR TO GND BAR TO GND BAR TO GND BK YL TO GND BAR 66234 RESISTOR TO LED RELAY CONTACT POS 1 SEE WT YL SEE AC DIAGRAM BAR TO GND BK WT YL GN VI BK WT YL GN BL WT GLOW TEMPERATURE PHOTO SENSOR BAR TO GND BK WT SPLICE B ...

Page 51: ...OR PRES SENSOR INPUT FOR ACC POS SENSOR N C INPUT FOR ATMOS SENSOR N C 12 11 10 9 8 7 6 5 4 2 1 3 SPEED SIG INPUT BK VI ELECTRONIC GOVERNOR 3 4 1 2 OR YL OR BK GY OR YL 1 0K 3 83K 1 1K 12V BATTERY 1 2 3 4 5 6 7 8 9 10 11 12 RD WT OR WHT YL WT BL BK YL WT YL RD VI ENGINE CONNECTOR GREEN TEMP COOLANT SWITCH BK WT GY YL SPLICE RD ALTERNATOR STARTER RD RD YL OIL PRESSURE WARNING SW N C SPLICE SPLICE S...

Page 52: ...n WINCH BK BK YL BL CONTACTOR 1 BATTERY GN BN BK BK RD BL YL 1 2 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 12 11 10 9 9 10 11 12 A B C BN UP DOWN SWITCH 1 BK VI BN BK VI BN BK VI TOP SWITCH DOWN STOP BOTTOM SWITCH UP STOP BK BK WT BN BL YL BK BK YL BK RD RELAY TIME DELAY N O N C COM 90596_A_07 19 16 ...

Page 53: ...WT WT WT BK WT VI YL WT AMBER L AMBER R MARKER MARKER VI YL BK WT TO FUEL CKT BN BN BN WT WT WT RING GND LICENSE PLATE PANEL LIGHT BK WT BK WT BK BK WT WT BK BN BN WT BK BN BN BN WT BK BN WT BN WT WT BN BN SPADE SPADE SPADE SPADE SPADE SPADE SPADE SPADE SPADE SPADE SPADE SPADE WT BN YL GN B C A D SPADE SPADE SPADE C B A D SPADE SPADE SPLICE SPLICE SPADE SPADE SPADE SPADE SPADE SPADE SPADE SPLICE S...

Page 54: ...Wiring Diagrams 50 Owner s Manual for MLT6SMD Light Tower This page intentionally left blank ...

Page 55: ...____________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________...

Page 56: ...________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ _______________________________________________...

Page 57: ...________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ _______________________________________________...

Page 58: ...________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ _______________________________________________...

Page 59: ......

Page 60: ...ghts reserved Specifications are subject to change without notice No reproduction allowed in any form without prior written consent from Generac Mobile Products LLC Generac Mobile Products LLC 215 Power Drive Berlin WI 54923 GeneracMobileProducts com 800 926 9768 920 361 4442 ...

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