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Related Manuals for Generac Power Systems MAGNUM MLT4200IF4V
Summary of Contents for Generac Power Systems MAGNUM MLT4200IF4V
- Page 1 LIGHT TOWER MLT4200IVF4 www.discount-equipment.com OPERATING MANUAL...
- Page 2 Discount-Equipment.com is your online resource for commercial and industrial quality parts and equipment sales. Locations: Florida (West Palm Beach): 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Check out our website at www.discount-equipment.com Can’t find what you need? Click on this link: http://www.discount-equipment.com/category/5443-parts/ and fill out the request form.
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Page 3: Introduction
INTRODUCTION This manual provides information and procedures to safely operate and maintain the Magnum Power Products LLC unit. For your own safety and protection from physical injury, carefully read, understand, and observe the safety instructions described in this manual. Keep a copy of this manual with the unit at all times. The information contained in this manual was based on machines in production at the time of publication. -
Page 4: Table Of Contents
TABLE OF CONTENTS Page INTRODUCTION ..........................2 SAFETY NOTES ..........................4 OPERATING SAFETY ........................4 ENGINE SAFETY..........................5 SERVICE SAFETY..........................6 TOWING SAFETY..........................6 REPORTING TRAILER SAFETY DEFECTS ..................7 SAFETY SYMBOL SUMMARY ......................8 SPECIFICATIONS..........................9 UNIT DIMENSIONS ......................... 10 UNIT SERIAL NUMBER LOCATIONS ..................... -
Page 5: Safety Notes
SAFETY NOTES This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. This manual contains DANGERS, WARNINGS, CAUTIONS, NOTICES and NOTES which must be followed to prevent the possibility of improper service, damage to the equipment, personal injury or death. -
Page 6: Engine Safety
• ALWAYS extend the outriggers and level the unit before raising the mast. DO NOT retract the outriggers while the mast is up. • If for any reason any part of the mast hangs up or the winch cable develops slack while raising or lowering the mast, STOP immediately and contact an authorized service representative. -
Page 7: Service Safety
SERVICE SAFETY This unit uses high voltage circuits capable of causing serious injury or death. Only a qualified electrician should troubleshoot or repair electrical problems occurring in this equipment. • Before servicing, make sure the Control Power switch and circuit breakers are in the OFF (O) position, and the negative terminal on the battery is disconnected. -
Page 8: Reporting Trailer Safety Defects
REPORTING TRAILER SAFETY DEFECTS If you believe your trailer has a defect which 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 Magnum Power Products LLC. -
Page 9: Safety Symbol Summary
SAFETY SYMBOL SUMMARY This equipment has been supplied with numerous safety and operating decals. These decals provide important operating instructions and warn of dangers and hazards. Replace any missing or hard-to-read decals and use care when washing or cleaning the unit. Decal placement and part numbers can be found in the parts manual. Below is a summary of the intended meanings for the symbols used on the decals. -
Page 10: Specifications
SPECIFICATIONS MAGNUM MODEL MLT4200IVF4 Engine Make/Brand..........................Isuzu Model ...........................4LE2TAGV-03 EPA Tier ..........................4f Horsepower - prime hp (kW) ....................36.2 (27.0) Horsepower - standby hp (kW)....................40.2 (30.0) Operating Speed rpm ......................1800 Displacement in (L) ......................133 (2.18) Cylinders - qty ........................4 Fuel Consumption - 100% prime gph (Lph) ................2.1 (7.8) Battery Type - Group Number ....................24 Battery Voltage (Quantity per Unit) ..................12V (1) Battery Rating ........................720 CCA... -
Page 11: Unit Dimensions
UNIT DIMENSIONS 00917 115 in 107 in 25 ft 68 in 140 in MLT4200IVF4 (2.92 m) (2.71 m) (7.6 m) (1.73 m) (3.56 m) Specifications are subject to change without notice. -
Page 12: Unit Serial Number Locations
Unit ID Tag Located on inside of front panel VIN Tag Manufactured by Magnum Power Products, LLC., a subsidiary of Generac Power Systems, Inc. TIRE AND LOADING INFORMATION (920) 361-4442 (800) 926-9768 MANUFACTURED BY/FABRIQUE PAR: Magnum Power Products LLC DATE:... -
Page 13: Component Locations
COMPONENT LOCATIONS Radiator Access Engine / Battery Access Emergency Stop Switch Fork Lift Control Pockets Panel Access Tongue Jack Leveling Jack/Outrigger Receptacle Panel Central Lift Point Fuel Fill Access Rear Jack Leveling Jack/Outrigger Engine Access 00919... -
Page 14: Light Tower Set Up
LIGHT TOWER SET UP 1. For maximum light coverage, locate the unit at ground level or in a spot higher than the area being illuminated by the lamps. WARNING The mast extends up to 25 ft (7.6 m). Make sure the area above the unit is open and clear of overhead wires and obstructions. -
Page 15: Raising The Mast
RAISING THE MAST 1. Set up and level the unit. Refer to “Component Locations” on page WARNING The unit must be leveled with the outriggers extended before raising the mast. The outriggers must remain extended while the mast is up. Failure to level the unit or extend the outriggers will severely reduce stability and could allow the unit to tip... -
Page 16: Main Control Panel
MAIN CONTROL PANEL MAIN BREAKER 240V BREAKER NEUTRAL BONDED TO FRAME 00896 1. L401 CONTROLLER: Refer to “L401 Controller” on page 2. MAIN CIRCUIT BREAKER: This 240V (100A) breaker will disconnect power to the lights and receptacles. 3. DC BREAKER: Circuit breaker (10A) for the engine electrical system. 4. -
Page 17: L401 Controller
L401 CONTROLLER The L401 controller is an auto start controller that monitors the unit and indicates operational status and fault conditions. The controller can be programmed to automatically start or stop based on time schedule, fault condition, or load demand. The controller constantly monitors vital generator and engine functions for a number of preprogrammed alarm and fault conditions. - Page 18 Icon Details Generator voltage and frequency screen Current and load screen Engine speed screen Hours run screen Battery voltage screen Oil pressure screen Coolant temperature screen Fuel sender screen Event log Current time held in the unit The current valve of the scheduler run time and duration ECU diagnostic trouble codes Oil filter maintenance timers Air filter maintenance timers...
- Page 19 Icon Details A timer is active (i.e. cranking time, crank rest, etc.) Engine is running, and all timers have expired, either on or off load. The animation speed is reduced when running in Idle mode. Unit is in the front panel editor USB connection is made to the controller Configuration file or engine file becomes corrupted Light Output Icons...
- Page 20 Icon Fault Description The measured current has risen above the configured trip level for a Delayed Over Current configured duration. The measured current has fallen below the configured trip level. This is Low Current used to detect lamp failure. Oil Filter Maintenance Alarm Maintenance due for oil filter. Air Filter Maintenance Alarm Maintenance due for air filter.
- Page 21 Icon Fault Description The measured current has risen above the configured trip level for a Delayed Over Current configured duration. The measured current has fallen below the configured trip level. This is Low Current used to detect lamp failure. Oil Filter Maintenance Alarm Maintenance due for oil filter. Air Filter Maintenance Alarm Maintenance due for air filter.
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Page 22: Operator Screens
CAUTION In case of an emergency, always press the emergency stop switch located on the side of the unit to stop the engine immediately. The Stop/Reset (O) button may delay the engine shutdown if stop faults exist. To prevent damage to the generator and connected equipment, remove all loads from the generator by opening all circuit breakers (turn to the OFF (O) position) before pressing the Stop/Reset (O) button. - Page 23 Icon Description Mast and light screens Engine DTCs (Diagnostic Trouble Codes) if active Event log HOME SCREEN The Home screen is the default screen of the controller and will display after the controller has powered up. The controller will automatically return to this screen from any other screen after a period of inactivity. 00897 ENGINE SCREENS The Engine screens will display the speed, run time, battery voltage, coolant temperature, oil pressure, fuel level...
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Page 24: Prestart Checklist
To exit the active DTC(s) alarm section, press the ↑ and ↓ buttons simultaneously to enter the navigation menu. Once entered, cycle to the desired operator screen. Icon Fault DTC Description The engine ECU has detected a fault not recognized by the con- Check Engine Fault troller, contact the engine manufacturer for support. -
Page 25: Engine Break-In Requirements
Ensure all covers are in place and secure. Ensure the emergency stop switch is pulled out. ENGINE BREAK-IN REQUIREMENTS Note: The EPA final tier 4 Isuzu engines have an engine break-in duration that will prohibit the unit from providing rated standby power upon factory delivery. -
Page 26: Auto (Remote) Starting Of The Unit
5. Should the engine not start and run within three starting cycles, the LCD window will show the Fail to Start alarm icon ( ). The starting sequence may be repeated after the starter has had a minimum of two minutes to cool. Pressing the Stop/Reset (O) button will clear the alarm and reset the controller. -
Page 27: Light Operation
LIGHT OPERATION The lights are turned on and off using the L401 controller. To view the mast and light screens, press both ↑ and ↓ buttons simultaneously, the navigation menu is then displayed. Once entered, cycle to the mast and light section and press the Auto button to enter. -
Page 28: Wet Stacking
WET STACKING The unit is powered by a diesel engine. Diesel engines are susceptible to wet stacking if lightly loaded. Wet stacking occurs when an engine is run at less than 30% of its full load capacity, causing unburned fuel to accumulate in the exhaust system. -
Page 29: Auto Exercise Timer
levels. DANGER FAILURE TO ISOLATE THE GENERATOR FROM THE NORMAL POWER UTILITY CAN CAUSE POTENTIALLY LETHAL VOLTAGE TO BACKFEED INTO THE UTILITY LINES. THIS MAY RESULT IN INJURY OR ELECTROCUTION OF UTILITY WORKERS NEARBY. MAKE SURE THE GENERATOR IS ISOLATED BY A TRANSFER SWITCH FROM ANY LOCAL UTILITY LINES. - Page 30 2. Push the ↑ button until the wrench ( ) icon is selected. Push the Auto button to enter the parameters. 3. Change the parameter number to enable the desired timer. When the correct parameter number is showing, press the Auto button to enter it. Press the Manual/Start (I) button to change it to 1 to enable the timer and press the Auto button to save it.
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Page 31: Shutting Down The Unit
Parameter Description Details Scheduler (5) Start Time 0:00:00 Scheduler (5) Start Day 0 (1=Monday) Scheduler (5) Start Week 1,2,3,4 Scheduler (5) Duration 0:00:00 Scheduler (6) Start Time 0:00:00 Scheduler (6) Start Day 0 (1=Monday) Scheduler (6) Start Week 1,2,3,4 Scheduler (6) Duration 0:00:00 Scheduler (7) Start Time 0:00:00... -
Page 32: Towing The Unit
CAUTION STOP IMMEDIATELY if the mast hangs up or the winch cable begins to develop slack. Excess slack in the cable could cause the mast to collapse, which could result in personal injury or equipment damage. Contact an authorized service center. Note: If the generator is not operational, and the batteries do not have enough power to lower the mast, it may be necessary to lower the mast manually. -
Page 33: Lifting The Unit
6. Make sure the mast cradle locking pin is in place. 7. Make sure the doors are properly latched. 8. If the unit is going to be driven over rough ground, remove the bulbs from the light fixtures. 9. Check for proper inflation of the trailer tires. Refer to “Specifications”... -
Page 34: General Maintenance
GENERAL MAINTENANCE Poorly maintained equipment can become a safety hazard. In order for the equipment to operate safely and properly over a long period of time, periodic maintenance and occasional repairs are necessary. NEVER perform routine service (oil/filter changes, cleaning, etc.) unless all electrical components are shut off. Before servicing the unit, always follow the instructions listed below. -
Page 35: Resetting The Maintenance Alarms
Use the schedule in the following table as a guide for regular maintenance intervals. 1000 Item Daily Hours Hours Hours Check Oil Level Check Coolant Level Check Fuel Level Drain Fuel Filter Check Tire Pressure Check All Electrical Connections ... -
Page 36: Jack Maintenance
PREVENTIVE MAINTENANCE SCHEDULE Semi-Annually Or After First Maintenance Activity Before Each Use After Each 25 Hours Operation Of Operation Check Fasteners Check Electrical Connections Clean And Grease Brake Assembly Check Motor Brushes Visually Check Winch And Control ... -
Page 37: Lower Radiator Hose Heater Option - Use And Maintenance
under extremely dusty or damp operating conditions. LOWER RADIATOR HOSE HEATER OPTION - USE AND MAINTENANCE CAUTION Improper use of the lower radiator hose heater could result in damage to the engine or personal injury. Do not modify the location of the lower radiator hose heater. The following points should be followed when operating a unit equipped with a lower radiator hose heater. -
Page 38: Mast Light Connections
4. Check the oil pressure sender. To identify corrective action, refer to the troubleshooting section of the engine operator’s manual provided with the unit. HIGH COOLANT TEMPERATURE SHUTDOWN 1. Check the coolant level in the overflow jug. 2. Restart the engine and read the coolant temperature to verify a high coolant temperature shutdown. Stop the engine immediately if the coolant temperature is 210°F (99°C) or more. -
Page 39: Ac Wiring Diagram
AC WIRING DIAGRAM 90544_B_08.28.14... -
Page 40: Ac Wiring Diagram - Receptacle Panel
AC WIRING DIAGRAM - RECEPTACLE PANEL (2x5-20R, 1xTT-30, 1xL14-30R, 2x14-50) 90317_ORG_07.06.11... -
Page 41: Ac Wiring Diagram - Receptacle Panel Options (1 Of 2)
AC WIRING DIAGRAM - RECEPTACLE PANEL OPTIONS (1 OF 2) 30 AMP 30 AMP 50 AMP 50 AMP CIRCUIT CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER BREAKER BREAKER 20 AMP 20 AMP CIRCUIT CIRCUIT BREAKER BREAKER 240 VOLT 240 VOLT 240 VOLT 240 VOLT 50 AMP 30 AMP... -
Page 42: Ac Wiring Diagram - Receptacle Panel Options (2 Of 2)
AC WIRING DIAGRAM - RECEPTACLE PANEL OPTIONS (2 OF 2) 30 AMP 30 AMP 30 AMP 50 AMP CIRCUIT CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER BREAKER BREAKER 20 AMP 20 AMP CIRCUIT CIRCUIT BREAKER BREAKER 240 VOLT 240 VOLT 240 VOLT 240 VOLT 30 AMP 30 AMP... -
Page 43: Dc Wiring Diagram
DC WIRING DIAGRAM 90545_A_09.19.14... -
Page 44: Dc Wiring Diagram - Electric Winch
DC WIRING DIAGRAM - ELECTRIC WINCH 90443_H_06.10.14... -
Page 45: Dc Wiring Diagram - Interior Light Option
DC WIRING DIAGRAM - INTERIOR LIGHT OPTION CONNECT TO RED WIRE 65002 10A CIRCUIT BREAKER FUSE LIGHT 90574_ORG_09.12.14 DC WIRING DIAGRAM - BATTERY DISCONNECT OPTION BATTERY DISCONNECT 12 V BATTERY 90575_ORG_09.12.14 DC WIRING DIAGRAM - BATTERY CHARGER OPTION 12 VOLT 2 AMP CHARGER GR/YL 68118_A_09.12.14... -
Page 46: Trailer Lights Wiring Diagram
TRAILER LIGHTS WIRING DIAGRAM 90341_B_12.20.13... -
Page 47: Service Log
Discount-Equipment.com is your online resource for commercial and industrial quality parts and equipment sales. Locations: Florida (West Palm Beach): 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Check out our website at www.discount-equipment.com Can’t find what you need? Click on this link: http://www.discount-equipment.com/category/5443-parts/ and fill out the request form. - Page 48 www.discount-equipment.com REV: A PART NO: 37098 10.09.14...