Generac Power Systems MAGNUM MLT4200IVF4 Owner's Manual
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Generac Power Systems MAGNUM MLT4200IVF4 Owner's Manual

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Owner's Manual
Light Tower
MLT4200IVF4
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Summary of Contents for Generac Power Systems MAGNUM MLT4200IVF4

  • Page 1 Owner’s Manual Light Tower MLT4200IVF4 For technical assistance contact: www.generacmobileproducts.com Technical Support 1-800-926-9768 SAVE THIS MANUAL FOR FUTURE REFERENCE...
  • Page 2 Use this page to record important information about your Light Tower Record the information found on your unit data label on this page. See unit serial number location (Unit Serial Unit Model Number Number Locations). The label plate is affixed to the inside partition, to the left of the control panel console.

  • Page 3: Table Of Contents

    Table of Contents Section 1: Safety Rules & General Preparing for Start-Up ........19 Information Select AUTO or MANUAL Mode .......19 Configure for Intended Use ........19 Introduction ............1 Emergency Stop Switch ........19 Read This Manual Thoroughly ........1 How to Obtain Service ..........1 Engine Break-In Requirements ......
  • Page 4 Table of Contents Section 5: Troubleshooting General Troubleshooting ........35 Troubleshooting 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...

  • Page 5: Section 1: Safety Rules & General Information

    Safety Rules & General Information Section 1: Safety Rules & General Information Introduction Safety Rules Thank you for purchasing a Generac Mobile Products LLC The manufacturer cannot anticipate every possible product. This unit has been designed to provide high circumstance that might involve a hazard. The warnings in performance, efficient operation, and years of use when this manual, and on tags and decals affixed to the unit are, maintained properly.

  • Page 6: General Hazards

    Safety Rules & General Information General Hazards Explosion and Fire Hazards DANGER DANGER Asphyxiation. Running engines produce Explosion and Fire. Fuel and vapors are carbon monoxide, a colorless, odorless, extremely flammable and explosive. Add fuel poisonous gas. Carbon monoxide, if not in a well ventilated area.

  • Page 7: Electrical Hazards

    Safety Rules & General Information Electrical Hazards Battery Hazards DANGER DANGER Electrocution. In the event of electrical accident, Electrocution. Do not wear jewelry while immediately shut power OFF. Use non-conductive working on this equipment. Doing so will implements to free victim from live conductor. Apply result in death or serious injury.

  • Page 8: Fuel Hazards

    Safety Rules & General Information Fuel Hazards Operating Safety DANGER Positioning the Unit Explosion and fire.Fuel and vapors are extremely DANGER flammable and explosive. No leakage of fuel is permitted. Keep fire and spark away. Failure to do High Voltage. Verify area above unit is clear of overhead wires and obstructions.

  • Page 9: Raising And Lowering The Mast

    Safety Rules & General Information Service Safety Raising and Lowering the Mast WARNING This unit uses high voltage circuits capable of causing serious injury or death. Only a qualified and licensed Electrocution. Do not set up or operate electrician should troubleshoot or repair problems this unit if severe weather is expected.

  • Page 10: Towing Safety

    Safety Rules & General Information Towing Safety Reporting Trailer Safety Defects Towing a trailer requires care. Both the trailer and vehicle If you believe your trailer has a defect which could cause must be in good condition and securely fastened to each a crash or could cause injury or death, you should other to reduce the possibility of an accident.

  • Page 11: Section 2: General Information

    General Information Section 2: General Information Specifications DESCRIPTION UNITS MLT4200IVF4 Engine Make/Brand — Isuzu Model — 4LE2TAGV-03 EPA Tier — Horsepower - prime hp (kW) 36.2 (27.0) Horsepower - standby hp (kW) 40.2 (30.0) Operating Speed 1800 Displacement 133 (2.18) Cylinders Fuel Consumption—100% gph (Lph)

  • Page 12: Unit Dimensions

    General Information Unit Dimensions 004760 Figure 2-1. Unit Dimensions 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) Specifications are subject to change without notice. Owner’s Manual for MLT4200IVF4 Light Tower...

  • Page 13: Unit Serial Number Locations

    General Information Unit Serial Number Locations Refer to the illustration to locate the unit ID tag and Vehicle Identification Number (VIN) tag on the unit. Important information, such as the unit serial number, model number, VIN and tire loading information are found on these tags. Record the information from these tags so it is available if the tags are lost or damaged.

  • Page 14: Component Locations

    General Information Component Locations 004762 Figure 2-3. Component Locations Radiator Access Rear Jack Engine/Battery Access Receptacle Pane Fork Lift Pockets Tongue Jack Central Lift Point Control Panel Access Fuel Fill Access Emergency Stop Switch Leveling Jack/Outrigger Owner’s Manual for MLT4200IVF4 Light Tower...

  • Page 15: Control Panel

    General Information Control Panel MAIN BREAKER 240V BREAKER NEUTRAL BONDED TO FRAME 00896 Figure 2-4. Control Panel Power Zone–DLA AC/Light Breakers (4) Main Circuit Breaker DC Breaker Control Power Switch Owner’s Manual for MLT4200IVF4 Light Tower...

  • Page 16: Power Zone-Dla

    General Information Power Zone–DLA engine will be shut down automatically and the LCD window will show the fault that caused the shutdown. To The Power Zone–DLA is an auto start controller that resume operation, the fault condition must be corrected. monitors the unit and indicates operational status and This controller also records a history of unit performance, fault conditions.

  • Page 17: Operator Screens

    General Information Operator Screens Figure 2-6. The operator screens display the most relevant and critical information an operator will need to properly configure and use the unit. From these six screens, the operator can access information necessary to operate the unit under normal conditions.. 002355 Figure 2-8.
  • Page 18 General Information Scheduler Screen Icon Description Figure 2-10. The Scheduler screen enables the About screen operator to program specific times for the lights to turn on and off. Once programmed, the Scheduler will start the To enter the navigation menu, use the following engine and illuminate the lights until the designated procedure: shutdown time.
  • Page 19 General Information Once this has occurred, the controller shuts the Maintenance Screen generator set down immediately to prevent further Figure 2-13. The Maintenance screen ( ) displays damage. the maintenance alarms configured into the controller. • DTC faults are displayed by the controller. The three alarms are for servicing the fuel filter, oil filter, and air filter.
  • Page 20 General Information About Screen 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. 003783 Figure 2-15. About Screen Owner’s Manual for MLT4200IVF4 Light Tower...

  • Page 21: Section 3: Operation

    Operation Section 3: Operation Light Tower Setup DETAIL C DETAIL D DETAIL G DETAIL H 004763 Figure 3-1. Set Up Outriggers and Jacks 4. A grounding stud (C) is located on the control box. For grounding requirements, follow the National DANGER Electrical Code (NEC), state, and local regulations.

  • Page 22: Prestart Checklist

    Operation Prestart Checklist DANGER Before starting the unit, all items in the prestart checklist must be completed. This checklist applies to both manual Electrocution. DO NOT use the unit if and remote starting of the unit. electrical cord is cut or worn through. Doing WARNING so will result in death or serious injury.

  • Page 23: Preparing For Start-Up

    Operation Configure for Intended Use As described in “General Information”, the engine in this WARNING unit runs at low speed when the LED lights are operating Personal Injury. Stop immediately if the mast hangs and no loads are connected to the 120 or 240V up or the winch cable develops slack.

  • Page 24: Engine Break-In Requirements

    Operation The switch will remain closed until it is pulled out. NOTE: The engine can be started from any screen. It may take a few seconds for the engine to run smoothly and reach 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.

  • Page 25: Light Operation

    Operation Light Operation with a clean cloth to avoid leaving any grease, oil residue, or fingerprints on the glass. Any residue can create a hot spot on the bulb, causing premature bulb WARNING failure. Burn hazard. Never operate lights with a damaged or missing lens cover.

  • Page 26: Remote Start Terminal Block

    Operation Breakers Located Behind The Panel 003983 003984 Figure 3-6. Location of Outlets Figure 3-7. Remote Start Terminal Block Transfer Switch 240V/30A Twist-lock 120V/20A GFCI When the unit is used as a standby power supply, it must be equipped with a transfer switch which isolates it from 240V/50A Twist-lock the utility’s distribution system.

  • Page 27: Auto Exercise Timer

    Operation 2. Push the ↑ button until the wrench icon is selected. Utility Meter Push the AUTO button to select it and enter the parameters. WHITE Incoming Utility Power 3. Adjust the parameter number to enable the desired GRAY Normal Utility Power Circuit timer.
  • Page 28 Operation Parameter Description Details Scheduler (1) Start Day 0 (1=Monday) Scheduler (1) Start Week 1,2,3,4 Scheduler (1) Duration 0:00:00 Scheduler (2) Start Time 0:00:00 Scheduler (2) Start Day 0 (1=Monday) Scheduler (2) Start Week 1,2,3,4 Scheduler (2) Duration 0:00:00 Scheduler (3) Start Time 0:00:00 Scheduler (3) Start Day 0 (1=Monday)

  • Page 29: Shutting Down The Unit

    Operation Parameter Description Details 1004 Year 0-99 Shutting Down the Unit 2. Verify the cooling system is full of the proper mixture of water and engine coolant before each Check with personnel using power supplied by the unit heater use. and let them know the power is going to be turned off.

  • Page 30: Lowering The Mast-Manually

    Operation NOTE: Generac Mobile Products strongly recommends position. Verify the locking pins snap into place. that the lights be removed from the mast and stowed for Release the outrigger locking pins and slide the transportation. outriggers into the trailer frame until the locking pins snap into place.

  • Page 31: Lifting The Unit

    Operation 11. Maximum recommended speed for highway towing is 45 mph (72 km/h). Recommended off-road towing speed is not to exceed 10 mph (16 km/h) or less, depending on the terrain. Lifting the Unit Follow these steps to prepare the unit for lifting: 1.
  • Page 32 Operation This page intentionally left blank. Owner’s Manual for MLT4200IVF4 Light Tower...

  • Page 33: Section 4: Maintenance

    Maintenance Section 4: Maintenance Emissions Information Verify the circuit breakers are OFF. Disconnect the negative (–) terminal on the battery. For warranty information, please refer to the diesel Activate (push in) the emergency stop switch. engine manual supplied with this unit. Attach a “Do Not Start”...

  • Page 34: Basic Maintenance Schedule

    Maintenance Basic Maintenance Schedule • Verify the safety pins for the mast lock rod and mast lock bar are present and secured with a Refer to the original equipment manufacturer’s operating chain. Check that the spring located in the mast manual for a complete list of maintenance requirements.
  • Page 35 Maintenance Table 4-1. Basic Maintenance Guide 1000 Item Daily Hours Hours Hours Check Oil Level  Check Coolant Level  Check Fuel Level  Drain Fuel Filter  Check Tire Pressure   Inspect Wheel Bearings  Check All Electrical Connections ...

  • Page 36: Resetting The Maintenance Alarms

    Maintenance Resetting the Maintenance • Check all mounting bolts and make sure they are tightened to the recommended torque values. Alarms Replace any damaged fasteners. The PowerZone–DLA will display a warning message • Periodically check all connections to be sure they when the unit is due for maintenance or service.

  • Page 37: Jack Maintenance

    Maintenance Jack Maintenance Trailer Wheel Bearings The following procedures should be performed at least The trailer axles are equipped with a grease zerk fitting to annually: For side-wind models, the internal gearing and allow lubrication of the wheel bearings without the need bushings of the jack must be kept lubricated.
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  • Page 39: Section 5: Troubleshooting

    Troubleshooting Section 5: Troubleshooting General Troubleshooting WARNING Risk of burns. Allow engine to cool before draining oil or coolant. Failure to do so could result in death or serious injury. (000139) Some of the more common problems are listed in the table below.

  • Page 40: Troubleshooting The Lights

    Troubleshooting Troubleshooting the Lights WARNING IMPORTANT NOTE: Only a qualified electrician should troubleshoot or repair electrical problems occurring in this Burn hazard. Lamps become extremely hot equipment. Contact Generac Mobile Products Technical while in use. Allow 10–15 minutes for cooling Service at 1-800-926-9768 for assistance if you have any before handling or lowering mast.

  • Page 41: Section 6: Wiring Diagrams

    Wiring Diagrams Section 6: Wiring Diagrams Mast Junction Box Wiring and Light Connections 00175 Owner’s Manual for MLT4200IVF4 Light Tower...

  • Page 42: Ac Wiring

    Wiring Diagrams AC Wiring YL 14AWG YL 14AWG TO CNTRL 9 BK/WT RD 14AWG RD 14AWG RD 14AWG TO CNTRL 8 BK/WT RD 14AWG BL 14AWG BL 14AWG BK 14AWG TO CNTRL 7 BK/WT BK 14AWG BK 14AWG BK 14AWG TO CNTRL 6 BK/WT 60HZ...

  • Page 43: Ac Wiring-Receptacle Panel

    Wiring Diagrams AC Wiring—Receptacle Panel TO MAIN BREAKER TO NEUTRAL TO GROUND (2x5-20R, 1xTT-30, 1xL14-30R, 2x14-50) 90317_ORG_07.06.11 Owner’s Manual for MLT4200IVF4 Light Tower...

  • Page 44: Ac Wiring-Receptacle Panel Options (1 Of 2)

    Wiring Diagrams AC Wiring—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 30 AMP 30 AMP 50 AMP...

  • Page 45: Ac Wiring-Receptacle Panel Options (2 Of 2)

    Wiring Diagrams AC Wiring—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 30 AMP...

  • Page 46: Dc Wiring

    Wiring Diagrams DC Wiring 90545_B_11.14.14 Owner’s Manual for MLT4200IVF4 Light Tower...

  • Page 47: Dc Wiring For Electric Winch

    Wiring Diagrams DC Wiring for Electric Winch 90443_H_06.10.14 Owner’s Manual for MLT4200IVF4 Light Tower...

  • Page 48: Dc Wiring For Optional Equipment

    Wiring Diagrams DC Wiring for Optional Equipment 90578_ORG_09.23.14 90323_K_06.04.14 Owner’s Manual for MLT4200IVF4 Light Tower...

  • Page 49: Trailer Lights Wiring

    Wiring Diagrams Trailer Lights Wiring SPADE SPADE 90341_B_12.20.13 Owner’s Manual for MLT4200IVF4 Light Tower...
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  • Page 51 Service Log Notes ______________________________________ OIL GRADE: ___________________________________ ______________________________________ COOLANT MIXTURE: ___________________________ ______________________________________ ______________________________________________ ______________________________________ ______________________________________________ ______________________________________ ______________________________________________ ______________________________________ ______________________________________________ ______________________________________ ______________________________________________ ______________________________________ ______________________________________________ ______________________________________ ______________________________________________ ______________________________________ ______________________________________________ ______________________________________ ______________________________________________ ______________________________________ Hours to Coolant Date Oil Level ______________________________________ Service Level ______________________________________ ______________________________________ ______________________________________ ______________________________________...
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  • Page 56 Part No. 37098 Rev. B 3/14/17 ©2017 Generac Mobile Products All rights reserved. Specifications are subject to change without notice. Generac Mobile Products No reproduction allowed in any form without prior written 215 Power Drive, Berlin, WI 54923 consent from Generac Mobile Products. GeneracMobileProducts.com │800-926-9768 │920-361-4442...

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