Page 1
Owner’s Manual
To order go to Discount-Equipment.com
Light Tower
MLT4200IF4
003975
SA VE THIS MANUAL FOR FUTURE REFERENCE
Page 2
TO PURCHASE THIS PRODUCT PLEASE CONTACT US
To order go to Discount-Equipment.com
Equipment Financing and
Extended Warranties Available
Discount-Equipment.com is your online resource for
commercial and industrial
561-964-4949
visit us on line @ www.discount-equipment.com
Select an option below to find your Equipment
quality parts and equipment sales.
We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman,
co, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power
May
Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,
Skytrak, Tsurumi, Husquvarna Target, Stow, Wacker, Sakai, Mi-T-M, Sullair, Basic, Dynapac,
MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti, Morrison, Contec,
Buddy, Crown, Edco, Wyco, Bomag, Laymor, EZ Trench, Bil-Jax, F.S. Curtis, Gehl Pavers, Heli,
Honda, 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
Page 3
Use this page to record important information about your Light Tower
(000005)
WARNING
California Proposition 65. This product contains or
emits chemicals known to the state of California to
cause cancer, birth defects, and other reproductive
harm.
(000004)
WARNING
California Proposition 65. Engine exhaust and some
of its constituents are known to the state of California
to cause cancer, birth defects, and other reproductive
harm.
To order go to Discount-Equipment.com
Record the information found on your unit data label on
Unit Model Number
Unit Serial Number
Engine Model
Number
Engine Serial
Number
Generator Model
Number
Generator Serial
Number
this page. See unit serial number location (Unit Serial
Number Locations). The label plate is affixed to the
inside partition, to the left of the control panel console.
Engine and generator serial numbers are located on
separate data plates affixed to the engine and generator
respectively.
When contacting a Generac Mobile Products Authorized
Service Dealer (GMP ASD) about parts and service,
always supply the complete model number and serial
number of the unit.
Operation and Maintenance: Proper maintenance and
care of the Light Tower ensures a minimum number of
problems and keeps operating expenses at a minimum. It
is the operator’s responsibility to perform all 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 operating habits and usage may
contribute to the need for additional maintenance or
service.
ii Owner’s Manual for MLT4200IF4 Light Tower
Page 4
Table of Contents
To order go to Discount-Equipment.com
Section 1: Safety Rules & General
Information
Introduction ..........................................................1
Read This Manual Thoroughly ....................................1
How to Obtain Service ............ ... ... ... .... ... ... ... .... ... ... ... ..1
Safety Rules .........................................................1
General Hazards ..................................................2
Explosion and Fire Hazards ................................2
Trailer Hazards .....................................................2
Electrical Hazards ................................................3
Battery Hazards ...................................................3
Fuel Hazards ........................................................4
Engine Safety .......................................................4
Operating Safety ..................................................4
Positioning the Unit .....................................................4
Starting the Unit ...........................................................4
Raising and Lowering the Mast ...................................5
Service Safety ......................................................5
Towing Safety ......................................................6
Hitch and Coupling .... ... ... ............................................6
Running Lights ............................................................6
Wheels and Tires ........................................................6
Safe Towing Techniques ........................................... ..6
Reporting Trailer Safety Defects ........................6
Safety and Operating Decals ..............................7
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 ................................................. 27
AUTO Exercise Timer ........................................28
Shutting Down the Unit .....................................29
Automatic Shutdown .................................................29
Lower Radiator Hose Heater (If Equipped) .....30
Use and Maintenance ...............................................30
Lowering the Mast .............................................30
Removing the Lights for Transportation .........30
Towing the Unit .................................................31
Lifting the Unit ...................................................32
Section 2: General Information
Specifications ....................................................11
Unit Dimensions ................................................12
Unit Serial Number Locations ..........................13
Component Locations .......................................14
Control Panel .....................................................15
Power Zone–DLA ...............................................16
Controller Features and Functions ............................16
Operator Screens ......................................................17
Section 3: Operation
Light Tower Setup .............................................21
Prestart Checklist ..............................................22
Owner’s Manual for MLT4200IF4 Light Tower 1
Section 4: Maintenance
Emissions Information ......................................33
Daily Walk-Around Inspection ......................... 33
General Maintenance ........................................33
Preparing for Service .................................................33
Cleaning the Unit ....... ... ... ... .... ... ... .............................33
Inspecting the Unit .....................................................33
Basic Maintenance Schedule ...........................34
Resetting the Maintenance Alarms ..................35
Winch Use, Operation and Maintenance .........35
Prior to Use ...............................................................35
Operation ...................................................................35
Maintenance ....................................... .......................35
Page 5
Table of Contents
To order go to Discount-Equipment.com
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
2 Owner’s Manual for MLT4200IF4 Light Tower
Page 6
Safety Rules & General Information
(000100a)
WARNING
Consult Manual. Read and understand manual
completely before using product. Failure to
completely understand manual and product
could result in death or serious injury.
(000001)
DANGER
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
(000002)
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
(000003)
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
To order go to Discount-Equipment.com
Section 1: Safety Rules & General Information
Introduction
Thank you for purchasing a Generac Mo bile Products LLC
product. This unit has been designed to provide high
performance, efficient operation, and years of use when
maintained properly.
The information in this manual is accurate based on
products produced at the time of publication. The
manufacturer reserves the right to make technical update s,
corrections, and product revisions at any time without
notice.
Read This Manual Thoroughly
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 ma nufacturer 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 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 incorrectly or carelessly. Observe them
carefully. Their definitions are as follows:
The owner is resp
use of the equipment. Comply with regulations the
Occupational Safety and Health Administration (OSHA)
has established, or with equivalent standards. Also, verify
that the unit is applied, used, and maintained in accordance
with the manufacturer's instructions and recommendations.
Do nothing that might alter safe application/usage and
render the unit in noncompliance with the aforementioned
codes, standards, laws, and regulations
Save these instructions for future reference. This manual
contains important instructions for the unit tha t shou ld be
followed during setup, operation and maintenance of the
unit and battery. ALWAYS supply this manual to any
individual that will use this machine.
onsible for proper maintenance and safe
.
NOTE: Notes contain additional information important to
a procedure and will be found within the regular text of
this manual.
These safety alerts cannot eliminate the hazards that they
indicate. Common sense and strict compliance with the
special instructions while performing the action or service
are essential to preventing accidents.
Owner’s Manual for MLT4200IF4 Light Tower 1
Page 7
Safety Rules & General Information
Asphyxiation. Running engines produce
carbon monoxide, a colorless, odorless,
poisonous gas. Carbon monoxide, if not
avoided, will result in death or serious injury.
(000103)
DANGER
(000107)
WARNING
Hearing Loss. Hearing protection is
recommended when using this machine.
Failure to wear hearing protection could
result in permanant hearing loss.
(000111)
WARNING
Moving Parts. Keep clothing, hair, and
appendages away from moving parts. Failure
to do so could result in death or serious injury.
(000108)
WARNING
Hot Surfaces. When operating machine, do not
touch hot surfaces. Keep machine away from
combustibles during use. Hot surfaces could
result in severe burns or fire.
(000182)
WARNING
Only qualified service personnel may install, operate,
and maintain this equipment. Failure to follow proper
installation requirements could result in death, serious
injury, and damage to equipment or property.
WARNING
Risk of injury. Do not operate or service this machine
if not fully alert. Fatigue can impair the ability to service
this equipment and could result in death 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 must be positioned in a
manner that prevents combustible material
accumulation underneath. Failure to do so
could result in death or serious injury.
(000110)
WARNING
Risk of Fire. Hot surfaces could ignite
combustibles, resulting in fire. Fire could
result in death or serious injury.
WARNING
Trailer must be securely coupled to the hitch and the
chains correctly attached. Uncoupled or unchained
towing could result in death or serious injury.
(000233)
WARNING
Do not operate this unit while transporting. Doing so
could result in death or serious injury.
(000231)
(000234a)
WARNING
Crushing hazard. Verify unit is properly secured and
on level ground. An unsecured unit can suddenly roll
or move, causing death or serious injury.
WARNING
Property or Equipment Damage. Tighten wheel lug
nuts after first 50 miles to factory specifications.
Failure to do so could result in death, serious injury,
property or equipment damage.
(000235)
To order go to Discount-Equipment.com
General Hazards Explosion and Fire Hazards
Trailer Hazards
2 Owner’s Manual for MLT4200IF4 Light Tower
Page 8
Safety Rules & General Information
(000145)
DANGER
Electrocution. In the event of electrical accident,
immediately shut power OFF. Use non-conductive
implements to free victim from live conductor. Apply
first aid and get medical help. Failure to do so will
result in death or serious injury.
(000104)
DANGER
Electrocution. Water contact with a power
source, if not avoided, will result in death
or serious injury.
(000144)
DANGER
Electrocution. Contact with bare wires,
terminals, and connections while generator
is running will result in death or serious injury.
(000152)
DANGER
Electrocution. Verify electrical system is
properly grounded before applying power.
Failure to do so will result in death or serious
injury.
(000188)
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)
WARNING
Explosion. Batteries emit explosive gases while charging.
Keep fire and spark away. Wear protective gear when
working with batteries. Failure to do so could result in
death or serious injury.
(000162)
WARNING
Explosion. Do not dispose of batteries in a fire. Batteries
are explosive. Electrolyte solution can cause burns and
blindness. If electrolyte contacts skin or eyes, flush with water
and seek immediate medical attention.
(000163a)
WARNING
Risk of burn. Do not open or mutilate batteries.
Batteries contain electrolyte solution which can
cause burns and blindness. If electrolyte contacts
skin or eyes, flush with water and seek immediate
medical attention.
WARNING
Environmental Hazard. Always recycle batteries at an
official recycling center in accordance with all local
laws and regulations. Failure to do so could result in
environmental damage, death or serious injury.
(000228)
To order go to Discount-Equipment.com
Electrical Hazards Battery Hazards
Always recycle batteries in accordance with local laws and
regulations. Contact your local solid waste collection site
or recycling facility to obtain information on local recycling
processes. For more information on battery recycling, visit
the Battery Council International website at: http://
batterycouncil.org
Owner’s Manual for MLT4200IF4 Light Tower 3
Page 9
Safety Rules & General Information
(000192)
DANGER
Explosion and fire.Fuel and vapors are extremely
flammable and explosive. No leakage of fuel is
permitted. 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.
(000260a)
High Voltage. Verify area above unit is clear
of overhead wires and obstructions. Contact
with high-voltage power lines will result in
death or serious injury.
DANGER
(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.
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)
CAUTION
(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
To order go to Discount-Equipment.com
Fuel Hazards
• DO NOT fill fuel tank near an open flame, while
smoking, or while engine is running. DO NOT fill
tank in an enclosed area with poor ventilation.
• DO NOT operate with the fuel tank cap loose or
missing.
Engine Safety
Internal combustion engines present special hazards
during operation and fueling. Failure to follow the safety
guidelines described below could result in severe injury or
death. Read and follow all safety alerts described in the
engine operator's manual. A copy of this manual was
supplied with the unit when it was shipped from the factory .
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
• DO NOT run engine indoors or in an area with poo r
ventilation. Make sure engine exhaust cannot seep
into closed rooms or ventilation equipment.
• DO NOT clean air filter with gasoline or other types
of low flash point solvents.
• DO NOT operate the unit without a functional
exhaust system.
• Shut the engine down if any of the following
conditions exist during operation:
• Abnormal change in engine speed.
• Loss of electrical output.
• Equipment connected to the unit overheats.
• Sparking occurs.
• Engine misfires or there is excessive engine/
generator vibration.
• Protective covers are loose or missing.
• Ambient air temperature is above 120°F (49°C).
4 Owner’s Manual for MLT4200IF4 Light Tower
Page 10
Safety Rules & General Information
WARNING
Electrocution. Do not set up or operate
this unit if severe weather is expected.
Lightning strikes can kill or cause severe injury
even if you are not touching the unit.
(000296)
WARNING
(000297)
> 60 mph> 60 mph
Do not set up the unit if high winds
are expected. High winds can cause the
unit to tip or fall, causing severe injury
or machine damage.
(000279)
Personal injury or equipment damage. Do not raise
or lower the mast while the unit is operating.
Doing so can break the lenses and cause the
lamps to shatter.
WARNING
WARNING
Personal Injury. Stop immediately if the mast hangs
up or the winch cable develops slack. Excess slack
could cause the mast to collapse, resulting in personal
injury or equipment damage.
(000265)
WARNING
Tipping hazard. Extend the outriggers and level the unit
before raising the mast. Keep the outriggers extended
while the mast is up. Failure to do so could cause the unit
to tip and fall and could result in death or serious injury.
(000266)
(000278)
WARNING
Burn hazard. Lamps become extremely hot
while in use. Allow 10–15 minutes for cooling
before handling or lowering mast. Touching a
hot lens or fixture can cause severe burns.
To order go to Discount-Equipment.com
Raising and Lowering the Mast
Service Safety
This unit uses high voltage circuits capable of causing
serious injury or death. Only a qualified and licensed
electrician should troubleshoot or repair problems
occurring in this equipment.
•
Before servicing the unit, verify the Control Power
switch and circuit breakers are in the OFF (O)
position, and the negative (-) terminal on the battery
is disconnected.
service (oil/filter changes, cleaning, etc.) unless all
electrical components are shut down.
•
ALWAYS
unit in damp conditions. Do not service the unit if your
skin or clothing is wet. Do not allow water to collect
around the base of the unit.
•
DO NOT
power washers, or steam cleaners. Water may
collect in the unit, causing damage to electrical parts.
•
Replace all missing and hard to read decals. Decals
provide important operating instructions 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.
use extreme caution when servicing this
wash the unit with high pressure hoses,
DO NOT
• 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. Always remain aware of
the position of other people around you when lifting
the equipmen
t.
perform even routine
Keep area around the unit clear of people while
•
raising and lowering the mast.
• ALWAYS lower the mast when not in use.
• The tower extends up to 30 ft (9.14 m). Verify area
above trailer is open and clear of overhead wires
and obstructions.
• If for any reason any part of mast hangs up or
winch cable develops slack while raising or
lowering tower, STOP immediately! Contact a
Generac Mobile Products Authorized Service
Dealer.
• NEVER remove safety pin or pull mast locking pin
while tower is up.
Owner’s Manual for MLT4200IF4 Light Tower 5
Page 11
Safety Rules & General Information
To order go to Discount-Equipment.com
Towing Safety
Towing a trailer requires care. Both the trailer and vehicle
must be in good condition and securely fastened to each
other to reduce the possibility of an accident. Some states
require that large trailers be registered and licensed.
Contact your local Department of Transportation office to
check on license requirements for your particular unit.
Hitch and Coupling
Verify the hitch and coupling on the towing vehicle
•
are rated equal to, or greater than, the trailer's
Gross Vehicle Weight Rating (GVWR).
• Verify the trailer hitch and the coupling are
compatible. Make sure the coupling is securely
fastened to the vehicle.
• DO NOT tow trailer using defective parts. Inspect
the hitch and coupling for wear or damage.
• Connect safety chains in a crossing pattern under
the tongue.
• 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.
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 Generac
Mobile Products LLC.
If NHTSA receives similar complaints, it may open an
investigation; and if it finds that 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
Generac 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; or write to:
Administrator
NHTSA
1200 New Jersey Avenue S.E.
Washington, DC 20590
Y ou can also obtain other inform ation about motor vehicle
safety from http://www.safercar.gov.
Running Lights
Verify directional and brake lights on the trailer are
connected and working properly
Wheels 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 to win g
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 space between
vehicles and avoid soft shoulders, curbs and
sudden lane changes.
6 Owner’s Manual for MLT4200IF4 Light Tower
Page 12
Safety Rules & General Information
To order go to Discount-Equipment.com
Safety and Operating Decals
See Figure 1-1 through Figure 1-3. This unit features
numerous safety and operating decals. These decals
provide important operating instructions and warn of
dangers and hazards. The following diagrams illustrate
decal locations and descriptions.
Replace any missing or hard-to-read decals and use care
when washing or cleaning the unit.
ID Description
1 Danger–Lower Tower Before Tilting Mast
2 Lift Points
3 Do Not Remove Bolt
4 Crushing Hazard
5 Secure Mast Before Lifting or Towing
6 Tie-Down Point
7 Danger–Electrocution, Consult Manual
Danger–Diesel Fuel, Asphyxiation, No Open
29
Flames, Consult Manual
30 Ultra Low Sulfur Fuel Only
31 Warning–Radiator Is Hot During Operation
32 Warning–Moving Parts, Hot Surface
33 Warning–Hot Surface
8 Warning–Tipping Hazard
9 Instruction–Align Before 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 Remote Start Terminal Locations
22 Danger–High Voltage, Consult Manual
23 Danger–Overhead Power Lines
24 Use Caution When Raising or Lowering Mast
25 Instruction–Towing Instructions
26 Primary Filter
27 Secondary Filter
28 High Voltage
Owner’s Manual for MLT4200IF4 Light Tower 7
Page 13
Safety Rules & General Information
Baje la torre completamente antes de inclinar
el mástil. Inclinar un mástil extendido podría
causar lesiones graves o la muerte.
Completely lower tower before tilting mast.
Tilting an extended mast could cause serious
injury or death.
DANGER
DANGER
GEFAHR
PELIGRO
Den Turm vollständig absenken, bevor der
Mast gekippt wird. Das Kippen eines
ausgefahrenen Masts kann zu schwerer
Verletzung oder Tod führen.
Abaisser complètement la tour avant de faire
basculer le mât. Le fait de basculer un mât
déployé peut entraîner des blessures graves,
voire la mort.
Align before tilting mast down!
Fluchten, bevor der Mast nach unten gekippt wird!
¡Alinee antes de inclinar el mástil hacia abajo!
Faire l’alignement avant de basculer le mât!
Secure mast in transport lock before
lifting or towing.
Den Mast im transportschloss arretieren,
bevor gehoben oder abgeschleppt wird.
Bloquer le mât avec un cadenas de
transport avant de le soulever ou de le
remorquer.
Fije el mástil en el sujetador de transporte
antes de levantarlo o remolcarlo.
Secure mast in transport lock before
lifting or towing.
Den Mast im transportschloss arretieren,
bevor gehoben oder abgeschleppt wird.
Bloquer le mât avec un cadenas de
transport avant de le soulever ou de le
remorquer.
Fije el mástil en el sujetador de transporte
antes de levantarlo o remolcarlo.
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
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- und Augenreizung
führen. Nur zusammen mit der mitgelieferten,
unbeschädigten Objektivkappe und
-vorrichtung verwenden.
La radiación ultravioleta de la lámpara
puede irritar gravemente los ojos y la piel.
Utilice solo con la cubierta y el accesorio
para lente no dañados que se proporcionan.
Les rayons UV de la lampe peuvent causer
de fortes irritations de la peau et des yeux.
N’utiliser qu’avec les protections et fixations
pour lentilles intactes fournies.
WARNUNG
ADVERTENCIA
AVERTISSEMENT
WARNING
A non-secured, falling mast will
cause serious injury or death if a
person is hit. To secure mast,
insert the lock bar into mast
mounted bracket then insert pin.
GEFAHR
PELIGRO
DANGER
Ein ungesicherter, fallender Mast
verursacht schwere Verletzungen
oder Tod, wenn er auf eine Person
trifft. Zur Sicherung des Masts eine
Sperrstange in den am Mast
angebrachten Bügel schieben
und dann den Sperrstift einsetzen.
Un mástil que cae que no está
asegurado causará lesiones
graves o la muerte si golpea a
una persona. Para sujetar el
mástil, inserte la barra de
seguridad dentro del soporte
montado en el mástil y luego
inserte el pasador.
Un mât non immobilisé qui chute
causera des blessures graves,
voire la mort, si une personne
est frappée. Pour immobiliser un
mât, insérer le pêne dans le
manchon du mât, puis insérer la
tige de blocage.
DANGER
1
2 3
4
5
6
7
8
9
6
5
4
10
11
11
6
12
13
14
15
To order go to Discount-Equipment.com
Figure 1-1. Decals - External
8 Owner’s Manual for MLT4200IF4 Light Tower
Page 14
Débrancher la batterie avant de faire l’entretien.
Disconnect battery before servicing.
Vor der Instandsetzung die Batterieverbindungen lösen.
Desconecte la batería
antes de realizar el servicio técnico.
×2
0°±5°
SET UP / AUFSTELLUNG / INSTALACIÓN / INSTALLATION
> 65 mph
15 MIN
STOP
×2
TAKE DOWN / ABBAU / DESINSTALACIÓN / DÉMONTAGE
WARNING
WARNUNG
ADVERTENCIA
AVERT ISSEM ENT
GEFAHR
PELIGRO
DANGER
DANGER
Der kontakt mit elektrischen
Hochspannungsleitungen 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 positionner la tour
lumineuse sous des câbles électriques.
Contact with overhead electrical power lines
will cause serious injury or death. Do not
position light tower under electrical power lines.
OVERHEAD POWER LINES
Located behind control
panel
Located on battery
16
17
18
19
20
21
22
23
To order go to Discount-Equipment.com
Safety Rules & General Information
Figure 1-2. Decals - Left Side and Interior
Owner’s Manual for MLT4200IF4 Light Tower 9
Page 15
Safety Rules & General Information
WARNING
WARNUNG
ADVERTENCIA
AVERTISSEMENT
DANGER
GEFAHR
PELIGRO
DANGER
DIESEL
SECONDARY
FILTER
PRIMARY
FILTER
WARNUNG
ADVERTENCIA
AVERTISSEMENT
WARNING
WARNUNG
ADVERTENCIA
AVERTISSEMENT
WARNING
6PJNJ
ULTRA LOW
SULFUR
FUEL ONLY
5HDGRSHUDWRUVPDQXDO
8VHKLWFKUDWHGIRUWUDLOHUVJURVVYHKLFOHZHLJKW
UDWLQJ
6HFXUHO\DWWDFKWUDLOHUWRWRZYHKLFOH
$WWDFKVDIHW\FKDLQVXVLQJDFURVVSDWWHUQ
$WWDFKEUHDNGRZQFKDLQWRYHKLFOH
&KHFNWUDLOHUOLJKWV
TOWING INSTRUCTIONS INSTRUCCIONES PARA REMOLQUE
/HDHOPDQXDOGHORSHUDGRU
8VHXQHQJDQFKHDGHFXDGRSDUDOD³FDSDFLGDG
GHSHVREUXWRGHOYHKtFXOR´GHOUHPROTXH
(QJDQFKHILUPHPHQWHHOUHPROTXHDOYHKtFXOR
GHUHPROTXH
(QJDQFKHODVFDGHQDVGHVHJXULGDGHQ
IRUPDFUX]DGD
(QJDQFKHDOYHKtFXORODFDGHQDGHHPHUJHQFLD
SDUDDYHUtDV
5HYLVHODVOXFHVGHOUHPROTXH
ABSCHLEPPANWEISUNGEN
/LUHOHPDQXHOGHO¶XWLOLVDWHXU
8WLOLVHUXQDWWHODJHFRQYHQDQWDXSRLGVQRPLQDO
EUXWGHODUHPRUTXH
$UULPHUVROLGHPHQWODUHPRUTXHDXYpKLFXOHWUDFWHXU
3RVHUOHVFKDvQHVGHVpFXULWpHQOHVFURLVDQW
)L[HUODFKDvQHGHUHPRUTXDJHDXYpKLFXOH
9pULILHUOHVIHX[GHODUHPRUTXH
INSTRUCTIONS DE REMORQUAGE
%HQXW]HUKDQGEXFKOHVHQ
$QKlQJHYRUULFKWXQJYHUZHQGHQGLHGHU
Ä*HVDPWEHWULHEVJHZLFKWVNODVVH´GHV
)DKU]HXJVHQWVSULFKW
$QKlQJHUVLFKHUDP
$EVFKOHSSIDKU]HXJEHIHVWLJHQ
6LFKHUKHLWVNHWWHQEHU.UHX]DQEULQJHQ
$EUHLNHWWHDP)DKU]HXJDQEULQJHQ
$QKlQJHUOHXFKWHQSUIHQ
25
26
27
28
28
29
30
31
32
33
To order go to Discount-Equipment.com
10 Owner’s Manual for MLT4200IF4 Light Tower
Figure 1-3. Decals - Right Side and Interior
Page 16
Section 2: General Information
To order go to Discount-Equipment.com
Specifications
DESCRIPTION UNITS MLT4200IF4
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
Cylinders qty 4
Fuel Consumption—100% gph (Lph) 2.1 (7.8)
Battery Type—Group Number — 24
Battery Voltage quantity per unit 12V (1)
Battery Rating CCA-hour 720
Generator
Make/Brand — Marathon Electric
Model — 334CSA3028
Type, Insulation — Brushless, H
Output kW (kVA) 20.0 (20.0)
Output Voltage volts 120/240, single phase
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
Voltage Regulation — +/-1%
Voltages Available 1Ø — 120, 240
Lighting
Lighting T ype — Metal Halide
Ballast Type — Coil & Core
Lumens — 440,000-462,000
Coverage
Trailer
Number of Axles 1
Capacity - Axle Rating lbs (kg) 3000 (1361)
Tire Size in 15
Hitch—Standard — 2" Ball
Maximum Tire Pressure psi 50
Specifications are subject to change without notice.
3
(L)
in
acres (m
2
)
General Information
133 (2.18)
5 - 7 (20,234 - 28,328)
Owner’s Manual for MLT4200IF4 Light Tower 11
Page 17
General Information
A
B
C
D
E
To order go to Discount-Equipment.com
Unit Dimensions
Figure 2-1. Unit Dimensions
ABCDE
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)
Specifications are subject to change without notice.
003976
12 Owner’s Manual for MLT4200IF4 Light Tower
Page 18
General Information
Unit ID Tag
Located on inside
of front panel
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.,
a subsidiary 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 / 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 APPLICABLES EN VERTU DU REGLEMENT SUR LA SECURITE DES VEHICULES AUTOMOBILES DU CANADA EN VIGUEUR A LA DATE SA
FABRICATION.
The weight of cargo should never exceed 0000KG (0000LBS)
Le poids du chargement ne doit jamais depasser 0000KG (0000LBS)
003977
Generac Mobile Products LLC
To order go to Discount-Equipment.com
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. When ordering parts or
requesting assistance, you may be asked to provide this information.
Figure 2-2. Serial Number Locations
Owner’s Manual for MLT4200IF4 Light Tower 13
Page 19
General Information
003978
A
B
C
D
E
F
G
H
I
J
K
H
L
M
To order go to Discount-Equipment.com
Component Locations
Figure 2-3. Component Locations
A Central Lift 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
14 Owner’s Manual for MLT4200IF4 Light Tower
Page 20
Control Panel
ON
ON
NEUTRAL BONDED TO FRAME
DC
BREAKER
MAIN
BREAKER
240V
E
D
A
B
C
To order go to Discount-Equipment.com
General Information
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
Owner’s Manual for MLT4200IF4 Light Tower 15
Page 21
General Information
Select
A
B
C
D
E
F
G
H
To order go to Discount-Equipment.com
Power Zone–DLA
The Power Zone–DLA 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. When a fault condition occurs, the
engine will be shut down automatically and the LCD
window will show the fault that caused the shutdown. To
resume operation, the fault condition must be corre ct ed .
This controller also records a history of unit performance,
which may be viewed at any time and will not be lost
when the controller is powered down.
Figure 2-5. Power Zone–DLA Layout
Controller Features and Functions
(A) The Liquid Crystal Display (LCD) Window
This window displays 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 start” status.
(E) Stop Button
This button shuts down the unit and puts the controller
into STOP mode, whether in MANUAL mode or AUTO
mode.
NOTE: To prevent damage to the generator and
connected equipment, remove all loads from the
generator by opening all circuit br e ake r s (t ur n t o t he OF F
[O] position) before pressing the stop button.
(F) Stop LED
This LED illuminates when the unit is in STOP mode and
flashes when an Electrical Trip and Shutdown Fault has
occurred.
(G) Select Button
This button confirms entries chosen in the various edit
menus and screens.
(H) Menu Navigation
These buttons (↑, ↓) are used to navigate through the
various operator screens.
16 Owner’s Manual for MLT4200IF4 Light Tower
Page 22
Operator Screens
002354
002544
002355
002327
To order go to Discount-Equipment.com
See 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..
Figure 2-6. Operator Screens Location
Home Screen
See Figure 2-7. The Home screen is the default screen
of the controller and displays after the controller is
powered up and the unit management software is
loaded. It 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 or not
the scheduler is enabled.
General Information
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 pressure. Normal
operating pressure is between 35-80 psi (241-552
kPa).
• TEMP: Displays engine coolant temperature.
Normal operating temperature of the unit is
between 100-230°F (38-110°C).
• FUEL LEVEL: Displays remaining fuel level as a
percentage of usable fuel tank capacity.
Lights Screen
See Figure 2-9. The Lights screen enables the operator
to turn the lights on and off. Refer to Light Operation for
more information.
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 2-9. Lights Screen
Owner’s Manual for MLT4200IF4 Light Tower 17
Page 23
General Information
002329
003779
003780
To order go to Discount-Equipment.com
Scheduler Screen
See Figure 2-10. The Scheduler screen enables the
operator to program specific times for the lights to turn on
and off. Once programmed, the Scheduler will start the
engine and illuminate the lights until the designated
shutdown time.
Figure 2-10. Scheduler Screen
Icon Description
About screen
To enter the navigation menu, use the following
procedure:
1. Press both the ↑ and ↓ buttons simultaneously.
2. To select the required icon, press the ↑ button to
cycle right and the ↓ button to cycle left until the
desired operator screen section is reached.
3. Once the desired icon is at the top, press the
Select () button to enter that operator screen
section.
NOTE: Every time the operator screens are entered, the
home icon will be located at the top of the screen.
Alarms 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.
NOTE: This feature will only work in AUTO mode.
Maintenance Screens
See Figure 2-11. The information displayed on the
maintenance screens can be used to identify, diagnose
and troubleshoot unit shutdown conditions and poor unit
performance..
Figure 2-11. Maintenance Screens
Icon Description
Home screen
Alarms screen
Maintenance screen
Event log screen
Figure 2-12. 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
are self-resetting when the fault condition is
removed.
• Electrical trips stop the generator in a controlled
manner. On initiation of the electrical trip condition,
the controller de-energizes all the outputs,
including the lights, to remove the load from the
generator. Once this has occurred, the controller
starts the cooling timer and allows the engine to
cool off-load before shutting down the engine.
• Shutdown alarms stop the generator immediately.
On initiation of the shutdown condition, the
controller de-energizes all the outputs, including
the lights, to remove the load from the generator.
18 Owner’s Manual for MLT4200IF4 Light Tower
Page 24
General Information
003781
003782
To order go to Discount-Equipment.com
Once this has occurred, the controller shuts the
generator set down immediately to prevent further
damage.
• DTC faults are displayed by the controller.
Table 2-1. Possible DTC Faults
Fault DTC Description
Check Engine
Fault
Low Oil Pressure
Underspeed
Overspeed
Low Fuel Level
Battery Under/
Over Voltage
To view the active alarms, repeatedly press the ↑ and ↓
buttons until the LCD window displays the alarm.
Continue to press the ↑ and ↓ buttons to cycle through
the alarms.
To exit the alarm screen, press the ↑ and ↓ buttons
simultaneously to enter the navigation menu. Once
entered, cycle to the desired operator screen.
A fault not recognized by the controller
has been detected. Contact the engine
manufacturer for support.
Engine oil pressure has fallen below
its configured low oil pressure alarm
level.
Engine speed has fallen below its
configured underspeed alarm level.
Engine speed has risen above its
configured overspeed alarm level.
Engine’s fuel level has fallen below its
configured low fuel level alarm.
Engine’s DC supply has fallen below
or risen above its configured alarm
level.
Maintenance Screen
See Figure 2-13. The Maintenance screen ( ) displays
the maintenance alarms configured into the controller.
The three alarms are for servicing the fuel filter, oil filter,
and air filter.
Figure 2-13. Maintenance 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.
NOTE: The alarm condition must be corrected before a
reset will take place. If the alarm condition remains, it is
not possible to reset the unit. The exception to this is the
Low Oil Pressure alarm and similar ‘active from safety on’
alarms, as the oil pressure is low with the engine at rest.
To clear alarms that stop the generator, refer to
Resetting the Maintenance Alarms.
NOTE: The LCD backlight is on if the unit has sufficient
voltage while the unit is turned on, unless the unit is
cranking. In this case, the backlight is turned off.
If the controller is left in STOP mode for a period of
inactivity, the controller enters POWER SAVE mode. To
‘wake’ the controller, press the Stop (O) button.
Figure 2-14. Event Log Screen
To view the event log:
1. Press both ↑ and ↓ buttons simultaneously to
display the navigation menu.
2. Cycle to the event log section and press the Auto
button to enter.
3. Repeatedly press the ↑ or ↓ buttons until the LCD
window displays the desired event.
Continuing to press down the ↑ or ↓ buttons will cycle
through past alarms. Eventually the most recent alarm
will display and the cycle begins again.
To exit the event log, press the ↑ and ↓ buttons
simultaneously to enter the navigation menu. Once
entered, cycle to the desired operator screen.
Owner’s Manual for MLT4200IF4 Light Tower 19
Page 25
General Information
003783
To order go to Discount-Equipment.com
About Screen
See 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
20 Owner’s Manual for MLT4200IF4 Light Tower
Page 26
Section 3: Operation
DETAIL C
DETAIL D
DETAIL G
DETAIL H
003980
H
J
H
F
A
G
E
D
C
B
D
E
(000260a)
High Voltage. Verify area above unit is clear
of overhead wires and obstructions. Contact
with high-voltage power lines will result in
death or serious injury.
DANGER
To order go to Discount-Equipment.com
Light Tower Setup
Operation
Figure 3-1. Set Up Outriggers and Jacks
1. For maximum light coverage, position the unit at
ground level or in a spot higher than the area being
illuminated by the lamps.
NOTE: The mast extends up to 30 ft (9.14 m).
2. See Figure 3-1. Place the unit on firm ground that
is relatively flat, and then block the wheels (A) to
keep it from moving. This will make it easier to level
the unit.
3. Pull the locking pin (B) on the tongue jack and
rotate the jack 90°. Reinstall the locking pin. Turn
the jack handle clockwise to raise the trailer tongue
off of the towing vehicle.
Owner’s Manual for MLT4200IF4 Light Tower 21
4. A grounding stud (C) is located on the control box.
For grounding requirements, follow the National
Electrical Code (NEC), state, and local regulations.
5. Pull the locking pin (D) on the outrigger (E) and pull
6. Pull the locking pin on the rear jack (F) and rotate
7. See Detail H. Before raising the mast, it may be
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.
the jack 90°. Reinstall the locking pin. Rotate the
jack handle clockwise to start leveling the trailer
(see Detail G). Adjust all four jacks by rotating their
handles (G) clockwise until they are firmly in
contact with the ground and the trailer is as level as
possible.
necessary to adjust the lamps. The lamps may be
adjusted up, down, left or right by simply aiming
them in the desired direction.
Page 27
Operation
(000100a)
WARNING
Consult Manual. Read and understand manual
completely before using product. Failure to
completely understand manual and product
could result in death or serious injury.
WARNING
Tipping hazard. Extend the outriggers and level the unit
before raising the mast. Keep the outriggers extended
while the mast is up. Failure to do so could cause the unit
to tip and fall and could result in death or serious injury.
(000266)
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)
DETAIL C
STOP
DETAIL E
DETAIL G
DETAIL A
B
G
F
H
A
E
C
B
D
To order go to Discount-Equipment.com
Prestart Checklist
Before starting the unit, all items in the prestart checklist
must be completed. This checklist applies to b oth manual
and remote starting of the unit.
Verify all maintenance pr ocedures ar e up to date. For
more information, refer to General Maintenance and
Table 4-1.
The unit must be level.
The unit must be dry. Look for water inside or near
the unit; dry if needed.
For grounding requirements, follow the National
Electrical Code (NEC), state, and local regulations.
Verify the Control Power switch is OFF (O).
Verify all circuit breakers are OFF (O).
Inspect all electrical cords; repair or replace any that
are cut, worn, or bare.
Verify all winch cables are in good condition and
centered on each pulley. Do not use if cables are
kinked or beginning to unravel.
Check oil, coolant, and fuel levels. For more
information, refer to General Maintenance.
Verify battery connections are secure.
Raising the Mast
1. Set up and level the unit. See Light Tower Setup.
Turn the battery disconne ct switch ON, if equipped.
Check the engine fan belt tension and condition.
Check the engine fan belt guard.
Check the engine exhaust system fo r loos e or rust ed
components.
Verify all covers are in place and secure.
22 Owner’s Manual for MLT4200IF4 Light Tower
003981
Figure 3-2. Pulley Locations
Page 28
Operation
WARNING
Tipping hazard. Do not extend the mast beyond the
colored mark on the second mast section. The unit
can become unstable and tip or fall, causing injury.
(000262)
WARNING
Personal Injury. Stop immediately if the mast hangs
up or the winch cable develops slack. Excess slack
could cause the mast to collapse, resulting in personal
injury or equipment damage.
(000265)
002354
To order go to Discount-Equipment.com
2. See Figure 3-2. Remove mast cradle locking pin
from mast cradle (A).
3. Check the mast cables for excessive wear or
damage. Verify the cables are properly centered in
each pulley (B). Check the electrical cord for
damage.
4. Remove the safety pin from the mast lock bar (C).
Using the handle for the lower mast winch (D),
raise the mast until it is vertical and the tab on the
mast is positioned into the mast lock. The mast
lock bar should snap into place automatically.
Secure the lock with the safety pin (E).
Use the winch (F) to slowly extend the mast, making
5.
sure that the coiled electrical cord is extending at
the top sections of the mast. STOP extending the
mast when the colored mark (G) on the second
mast section is visible as seen in Detail G.
6.
The mast can be rotated by loosening the locking
knob at the bottom of the mast (H). Turn the mast
until the lights face in the desired direction and then
tighten the mast rotation knob to secure the mast in
position.
Preparing for Start-Up
NOTE:
drained, it may be necessary to bleed the fuel lines before
starting. Refer to the engine manual supplied with the unit.
Select AUTO or MANUAL Mode
See Figure 3-3. Using the arrows on the Power Zone–
DLA, select either AUTO or MANUAL on the Home
screen.
If the engine was run out of fuel or the fuel tank was
• 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 when the LED lights are operating
and no loads are connected to the 120 or 240V
convenience outlets. The engine runs at high speed
IMPORTANT NOTE: Contact a Generac Mobile
Products Authorized Service Dealer immediately if
the mast hangs up or the winch cable develops
slack.
Owner’s Manual for MLT4200IF4 Light Tower 23
when the LED lights are turned off. Therefore, before
starting, determine if auxiliary equipment will be
connected to the convenience outlets. Then set up the
unit based on the intended use:
LED Lights Only
Turn the 240V outlet breaker OFF. The engine will run at
low speed while operating, greatly reducing sound
emissions and fuel consumption.
LED Lights and Export Power
Turn the 240V outlet breaker ON and Load Sense OFF.
The engine will run at high speed for powering high
amperage equipment.
LED Lights and Export Power with Load Sense
Turn the 240V outlet breaker ON and Load Sense ON.
The engine will run at high speed when detecting applied
load(s) such as hand tools and low amperage equipment.
Page 29
TO PURCHASE THIS PRODUCT PLEASE CONTACT US
To order go to Discount-Equipment.com
Equipment Financing and
Extended Warranties Available
Discount-Equipment.com is your online resource for
commercial and industrial
561-964-4949
visit us on line @ www.discount-equipment.com
Select an option below to find your Equipment
quality parts and equipment sales.
We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman,
co, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power
May
Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,
Skytrak, Tsurumi, Husquvarna Target, Stow, Wacker, Sakai, Mi-T-M, Sullair, Basic, Dynapac,
MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti, Morrison, Contec,
Buddy, Crown, Edco, Wyco, Bomag, Laymor, EZ Trench, Bil-Jax, F.S. Curtis, Gehl Pavers, Heli,
Honda, 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
Page 30
Operation
002393
To order go to Discount-Equipment.com
Table 3-1 illustrates the four possible combinations of
240V outlet breaker and Load Sense switch positions.
Table 3-1. Engine Speed Selection
Load Sense Switch
ON OFF
Load
240VAC
Outlet
Breaker
*Engine will speed up automatically when more
ON
OFF Low speed Low speed
power is drawn from receptacles.
dependent—
variable speed*
High speed
Emergency Stop Switch
The unit is equipped with one emergency stop switch.
For location of the emergency stop switch, refer to
Component Locations. The red switch is clearly labeled
EMERGENCY STOP. The switch can be accessed and
activated with all doors closed and locked.
Activate the emergency stop switch by pushing the red
button in until it locks down. This will trip the main circuit
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.
power after the complete engine break-in period of 70
hours of loaded operation.
Operate the engine at heavy loads (60-90% [24-36kW] of
rated output maximum) as much as possible during the
break-in period.If the engine has spent significant time at
idle, constant speed(s) and/or light load or if makeup oil
is required, a longer break-in period may be needed.
Refer to the engines operator’s manual for a full
description of necessary procedures on the addition of oil
and extension of the break-in period. For 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 screen
displays on the LCD screen and the Stop LED
illuminates to indicate that the controller is in STOP
mode. Press the Start button to initiate the startup
procedure. Assuming there are no existing engine
faults, the engine will start and the Start LED will
illuminate.
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.
Figure 3-4. 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.
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 facto ry delivery. The
unit is tested at the factory and is initially capable of a
prime standby power output. The engine performance
will increase to 95% of full rated power during the first 20
hours of loaded operation. The unit will provide full rated
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. The controller backlight
will go out. The engine will make two more
attempts to start for a total of three crank cycles.
5. If the engine does not start and run within three
starting cycles, the LCD screen will display the
“Fail to Start” alarm. The starting sequence can be
repeated after the starter cools for at least two
minutes. Pressing the Stop (O) button will clear the
alarm and reset the controller.
Auto (Remote) Starting of the
Unit
Auto mode is used when the unit is started from a
location other than the control panel by using a transfer
switch. Auto (remote start) is the normal setting when the
generator is being used as a standby power supply.
Before putting the unit in the Auto mode, review the
Prestart Checklist and Manually Starting the Unit.
Also following any warnings and information on isolating
24 Owner’s Manual for MLT4200IF4 Light Tower
Page 31
Operation
(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.
(000278)
WARNING
Burn hazard. Lamps become extremely hot
while in use. Allow 10–15 minutes for cooling
before handling or lowering mast. Touching a
hot lens or fixture can cause severe burns.
002327
To order go to Discount-Equipment.com
the generator with a transfer switch if the unit is to be
used as a standby power supply. Then continue with the
steps described below:
1. Perform a manual start of the unit at least once to
verify that the engine is operating correctly.
NOTE: The lights are automatically disconnected on
startup. The main circuit breaker can be left o n if no othe r
loads are connected, except for the lights. Any connected
external loads must be disconnected by a transfer switch
when starting the unit.
2. If a check of the remove start circuit is desired:
a. Remove the wires from the remote start terminal
block. Press the Auto button. The Auto LED with
be lit.
b. Attach a jumper wire (minimum 16 gauge)
across the two terminals on the remote start
terminal block. This applies a ground to the
controller to close the starting circuit contacts.
The engine should crank, start and run.
c. Remove the jumper wire form the remote start
terminal block and the engine will stop.
d. Reconnect any necessary wires form the remote
start switch (transfer switch) to the remote start
terminal block.
3. Confirm the unit is in Auto mode. The Auto LED
should be lit.
4. Secure the unit by closing and locking all access
doors.
5. The unit is now ready for remote starting
Light Operation
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 or 1050W
bulbs. When checking or replacing the bulbs, wipe them
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
failure.
Engine Derating
All units are subject to derating for altitude and
temperature. Derating reduces the available power for
operating tools and accessories connected to the
receptacles. Typical reductions in performance are 2-4%
for every 1000 ft (305 m) of elevation and 1% per 10ºF
(5.6ºC) increase in ambient air temperature over 72ºF
(22ºC).
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
automatically in AUTO mode.
1. Once the engine is up to temper ature and running
Owner’s Manual for MLT4200IF4 Light Tower 25
smoothly, switch the main circuit breaker ON
(I).
Wet Stacking
The unit is powered by a diesel engine. Diesel engines
are subject 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. Wet stacking can be
detected by continuous black exhaust when the unit is
under a constant load. It can also cause fouling of
injectors and buildup on engine valves. Diesel engines
Page 32
Operation
A
C
B
006983
003984
A
(000226a)
Phase rotation must be compatible.
Incompatible phase rotation could result
in equipment damage, death or serious injury.
WARNING
To order go to Discount-Equipment.com
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 Regulation
Units are equipped with an electronic voltage regulator.
The voltage regulator controls the output of the ge nerato r
by regulating the current into the exciter field. The
regulator has three screwdriver adjustable
potentiometers that may be adjusted for voltage, stability
and voltage roll-off (U/F). The voltage regulator is
adjusted before shipment from the factory. Contact
Generac Mobile Products LLC for additional information
before attempting to adjust the voltage regulator.
Customer Convenience Outlets
See Figure 3-6. The unit is equipped with six
convenience outlets for powering accessories or tools
from the generator. Power is supplied to the outlets any
time the engine is running and the main circuit breaker is
switched ON (I). Each outlet has an individual circuit
breaker, located behind the outlet panel.
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 the
unit to be started by a remote dry-contact closure switch.
Before entering AUTO mode, verify that the contacts on
any remote switch linked to the unit are OPEN. If the
contacts on a remote switch are closed, the engine will
crank and start when AUTO mode is entered. Attach the
switch leads to the two unused terminals on the unit’s
remote start terminal block. For more information, refer to
Auto (Remote) Starting of the Unit.
Breakers Located
Behind The Panel
Figure 3-7. Remote Start Terminal Block
Transfer Switch
When the unit is used as a standby power supply, it must
be equipped with a transfer switch which isolates it from
the utility’s distribution system. A transfer switch is
designed to transfer electrical loads from the normal
power source (utility) 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
Figure 3-6. Location of Outlets
A 240V/30A Twist-lock
B 120V/20A GFCI
C 240V/50A Twist-lock
See Figure 3-6. The circuit breakers are labeled with the
corresponding voltage for the receptacle they protect.
With all of the lights OFF, full generator power output is
available to the receptacles.
NOTE: All equipment or load panels connected to the
generator MUST be properly grounded. If these
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.
26 Owner’s Manual for MLT4200IF4 Light Tower
to operating levels.)
Page 33
Operation
C
D
E
F
002807
A
B
(000150)
DANGER
Electrocution. Never connect this unit to the electrical
system of any building unless a licensed electrician
has installed an approved transfer switch. Failure to
do so will result in death or serious injury.
(000155)
WARNING
Only a trained and licensed electrician should perform
wiring and connections to unit. Failure to follow proper
installation requirements could result in death, serious
injury, and damage to equipment or property.
To order go to Discount-Equipment.com
AUTO Exercise Timer
The controller is capable of starting and stopping the unit
automatically, based on a programmable schedule. Units
installed in a standby application should be exercised
regularly to maintain operating condition and to ensure
responsiveness in an emergency situation. Use the
following procedures to operate the unit in AUTO mode:
NOTE: The controller must be in AUTO mode to run at
the programmed time. Use a trickle or solar battery
charger to prevent the controller from draining the battery
while in AUTO mode.
Figure 3-8. Transfer Switch Operation
A Incoming Utility Power
B
C Main Distribution Panel (Utility Power)
D T ransfer Switch
E Power From Generator
F Utility Meter
WHITE Incoming Utility Power
GRAY Normal Utility Power Circuit
BLACK Emergency Generator Power Circuit
Installation of a transfer switch or other type of remote
starting device is the responsibility of the user. Installation
of such devices must be performed by following all
directions supplied by the manu facturer of the switch. If
attaching the unit to a power supply normally serviced by
a utility company, notify the utility company and check
local and state regulations. Familiarize yourself with all
instructions and warning labels supplied with the switch.
Emergency Distribution Panel (Generator
Power)
1. Push both the STOP/RESET (O) and AUTO buttons simultaneously.
2. Push the ↑ button until the wrench icon is selected.
Push the AUTO button to select it and enter the
parameters.
3. Adjust the parameter number to ena ble th e de sired
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.
NOTE: The ↑ and ↓ buttons will adjust the hundredths
place of the parameter number and the MANUAL/START
(I) and STOP/RESET (O) buttons will adjust the low
digits. Up to eight events can be scheduled at a time.
4. Adjust the parameter 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) button to change to the desired day and press
the AUTO button to save it.
NOTE: Only one day can be chosen per event if
parameter 903 is “1” (monthly).
6. Adjust the parameter number to adjust duration of
the timer and press the AUTO button to enter it.
Press the MANUAL/START (I) or STOP/RESET
(O) buttons to change the duration and press the
AUTO button to save it.
NOTE: If any of the scheduled time slots are currently
active, the controller will begin the starting sequence and
Owner’s Manual for MLT4200IF4 Light Tower 27
start the unit provided there are no shutdown conditions
present.
The times for the scheduled timers and events are based
on the internal clock for the controller. Use the
corresponding parameters to ad jus t to t he co rrec t ti me of
the day and correct date.
Page 34
Operation
To order go to Discount-Equipment.com
This table lists the parameters needed to schedule an
event and to adjust the clock within the controller.
Parameter Description Details
Configuration Parameters - Scheduler
901 Enable Scheduler On (1), Off (0)
902 Schedule Run On or Off Load On (1), Off (0)
903 Schedule Period Weekly (0), Monthly (1)
904 Scheduler (1) Start Time 0:00:00
905 Scheduler (1) Start Day 0 (1=Monday)
906 Scheduler (1) Start Week 1,2,3,4
907 Scheduler (1) Dura tion 0:00:00
908 Scheduler (2) Start Time 0:00:00
909 Scheduler (2) Start Day 0 (1=Monday)
910 Scheduler (2) Start Week 1,2,3,4
911 Scheduler (2) Duration 0:00:00
NOTE: If parameter 902 is “0”, then the auto exercise
timer is enabled and if it is “1”, then the autolight timer is
enabled.
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) Dura tion 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) Dura tion 0:00:00
920 Scheduler (5) Start Time 0:00:00
921 Scheduler (5) Start Day 0 (1=Monday)
922 Scheduler (5) Start Week 1,2,3,4
923 Scheduler (5) Dura tion 0:00:00
924 Scheduler (6) Start Time 0:00:00
925 Scheduler (6) Start Day 0 (1=Monday)
926 Scheduler (6) Start Week 1,2,3,4
927 Scheduler (6) Dura tion 0:00:00
928 Scheduler (7) Start Time 0:00:00
929 Scheduler (7) Start Day 0 (1=Monday)
930 Scheduler (7) Start Week 1,2,3,4
931 Scheduler (7) Dura tion 0:00:00
932 Scheduler (8) Start Time 0:00:00
28 Owner’s Manual for MLT4200IF4 Light Tower
Page 35
Parameter Description Details
To order go to Discount-Equipment.com
933 Scheduler (8) Start Day 0 (1=Monday)
934 Scheduler (8 ) Sta rt Week 1,2,3,4
935 Scheduler (8) Duration 0:00:00
Configuration Parameters - Time and Date
1001 Time of Day 0:00:00
1002 Day of Month 1-31
1003 Month of Year 1-12
1004 Year 0-99
Operation
Shutting Down the Unit
Check with personnel using power supplied by the unit
and let them know the power is going to be turned off.
Verify the power shutdown will not create any hazards by
accidentally turning off equipment that needs to remain
running (pumps, compressors, lights, etc.).
1. Remove all loads from the outlets.
2. Turn the lights OFF using the controller.
3. Switch the outlet breaker OFF (O).
4. Press the Stop (O) button.
5. After the unit shuts down, switch the Control Power
switch breaker OFF (O).
NOTE: Disconnect the battery if the unit is to be stored
for an extended period. Refer to the engine operator’s
manual for additional extended storage procedures.
Automatic Shutdown
This unit is equipped with a low oil pressure and high
coolant temperature automatic shutdown system. This
system will automatically shut off the fuel supply to stop
the engine if oil pressure drops too low or the engine
exceeds normal operating temperature. Return the
Control Power switch to the STOP position to reset the
unit after the cause of shutdown has been determined.
NOTE: The unit will turn off the lights at the stop time, but
the engine will continue to run for up to five minutes as a
cool down. If the stop button is pressed, the unit will
immediately stop.
Lower Radiator Hose Heater (If
Equipped)
Use and Maintenance
The lower radiator hose heater is designed to prevent
engine coolant from freezing in extreme cold weather
conditions. While the heater 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 proper
orientation of the heater while it is in operation.
2. Verify the cooling system is full of the proper
mixture of water and engine coolant before each
heater use.
3. Use only an undamaged, outdoor rated, threeprong grounded 120VAC extension cord with a
minimum amperage rating of 10A. Connect the
cord to a properly grounded 120VAC, GFCI outlet.
4. Before starting the engine, unplug the extension
cord from the power first, then unplug the heater
cord set from the extension cord.
Lowering the Mast
1. Shut down the lights and engine. See Shutting
Down the Unit. Allow the lights to cool 10-15
minutes before lowering the mast.
2. Loosen the mast rotation knob. Rotate the mast
until the white arrows are aligned and the metal
stop tabs are touching. Tighten the mast rotation
knob.
3. Turn the upper mast winch handle
counterclockwise to collapse the mast to its lowest
position. verify the electrical cord does not get
caught in, or pinched by, the mast while it is being
lowered.
Owner’s Manual for MLT4200IF4 Light Tower 29
Page 36
Operation
WARNING
Personal Injury. Stop immediately if the mast hangs
up or the winch cable develops slack. Excess slack
could cause the mast to collapse, resulting in personal
injury or equipment damage.
(000265)
004481
To order go to Discount-Equipment.com
IMPORTANT NOTE: Contact an Generac Mobile
Products Authorized Service Dealer immediately if
the mast hangs up or the winch cable develops
slack.
4. Release the mast lock by pulling the safety pin on
the mast lock and pulling the lock bar free. Turn the
handle of the lower mast winch counterclockwise
until the mast rests in the transport cradle.
NOTE: If the mast lock bar does not 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.
f the unit is going to be moved, remove the lights
6. I
from the mast and stow for transportation
Removing the Lights for Transportation.
. See
Removing the Lights for
Transportation
1. See Figure 3-9. On units equipped with quick
disconnect fittings for the lights, disconnect the
power cords from the junction box at the top of the
st.
ma
2. Replace the dust caps on the junction box. On
other units, remove the junction box cover on the
top of the mast and disconnect ONLY the mast
light wires from the terminal blocks.
3. To release the wires from the terminal block s, flip
the locking levers down and pull out the
appropriate wires.
4. Remove the lights by removing the wing nut that
holds the light fixture bracket to the cross tube
5. Attach the lights to the storage brackets (if
equipped) located on the mast tube on either side
of the central lifting eye.
NOTE: Whe n installing the lights, verify th e star washer
is in place between the trunnion and T-handle before
tightening.
30 Owner’s Manual for MLT4200IF4 Light Tower
.
Towing the Unit
Once the engine is shut down and the mast and lights are
properly stowed, follow 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 into the trailer frame until the locking
pins snap into place.
3. Use the tongue jack to raise or lower the trailer
onto the hitch of the towing vehicle. Lock the hitch
coupling and attach the safety chains or cables to
the vehicle. Remove the tongue jack locking pin
and rotate the jack into the travel position. Replace
the locking pin.
NOTE: A film of grease on the coupler will extend
coupler life and eliminate squeaking. Wipe the coupler
clean and apply fresh grease each time the unit is towed.
4. To ensure proper operation of the jacks, lubricate
the grease fittings located on the leveling jacks.
Refer to Jack Maintenance. For maintenance
interval information, refer to Table 4-1.
5. Connect any trailer wiring to the tow vehicle. Chec
for proper operation of the directional and brake
lights.
6. Verify the cradle locking pin is in place.
7. Verify the enclosure and 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. For
maximum tire pressures, refer to Specifications.
10. See Figure 3-10. Check the wheel lugs. Tighten or
replace any lugs that are loose or missing. If a tire
has been removed for axle service or replaced,
Figure 3-9. Removing Lights
k
Page 37
Operation
5
2
3
4
1
003754
B
B
A
003985
To order go to Discount-Equipment.com
tighten the lugs, in the order shown, to the
following specifications:
Figure 3-10. Tightening Wheel Lugs
a. Start all lug nuts by hand.
b. First pass: tighten to 20-25 ft-lbs (27-33 Nm).
c. Second pass: tighten to 50-60 ft-lbs (67-81 Nm).
d. Third pass: tighten to 90-120 ft-lbs (122-162 Nm).
NOTE: After the first road use, re-torque the lug nuts in
sequence.
Lifting the Unit
Follow these steps to prepare the unit for lifting:
1. Verify the equipment 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 lifting the unit, attach any slings, chains or
hooks directly to the central lift point (A).
• Use the forklift pockets (B) with care. Lift only from
the side. Avoid approaching the unit at an angle,
as this can permanently damage the forklift
pockets, tires, or cabinet. Verify the forklift tines
are clear of any obstructions before lifting.
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.
Figure 3-11. Lift Points
Owner’s Manual for MLT4200IF4 Light Tower 31
Page 38
Operation
To order go to Discount-Equipment.com
This page intentionally left blank.
32 Owner’s Manual for MLT4200IF4 Light Tower
Page 39
Section 4: Maintenance
CAUTION
(000306)
Equipment Damage. Failure to perform a daily
inspection could result in damage to the unit.
004551
To order go to Discount-Equipment.com
Maintenance
Emissions Information
For warranty information, please refer to the diesel
engine manual supplied with this unit.
Daily Walk-Around Inspection
Perform a walk-around inspection of the unit every day
before starting the unit. Look for conditions that could
hinder performance or safety, such as (but not limited to):
• Oil, coolant and fuel leakage
• Blocked vents
• Loose or missing hardware
• Loose or broken electrical connections.
Inspect the fan belt for cracks, fraying, or stretching.
Verify the belt is properly seated in the pulley grooves.
Replace the belt according to the manufacturer’s
recommendations.
2. Verify the circuit breakers are OFF.
3. Disconne ct the nega tive (–) term inal on th e 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
inadvertently trying to start the unit.
Cleaning the Unit
Always clean the Light To wer 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. Lowpressure 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 components that
can be damaged by high pressure and heat. Therefore:
• Do not wash the unit with a high pressure hose or
power washer.
• Do not wash the engine block or fuel tank with a
power washer or steam cleaner. Water may enter
the cabinet and collect in the generator windings or
other electrical parts, causing dama
ge.
Inspecting the Unit
•
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. DO NOT perform
routine service (oil and filter changes, cleaning, etc.)
unless all electrical components are shut off.
Regular maintenance will improve performance and
extend engine/equipment life. Generac Mobile Products
LLC recommends that all maintenance work be
performed by a Generac Mobile Products Authorized
Service Dealer. Regular maintenance, replacement or
repair of the emissions control devices and systems may
be performed by any repair shop or person of the own er’s
choosing. However, to obtain emissions control warranty
service free of charge, the work must be performed by a
Generac Mobile Products Authorized Service Dealer or
authorized Mitsubishi engine dealer depending on the
repair. See the emissions warranty.
If the unit is stored outside, check for water inside
the cabinet and generator before each use. If wet,
dry the unit thoroughly before starting.
• Inspect condition of electrical cords. DO NOT use
the unit if insulation is cut or worn through.
• Verify winch cables are in good condition and
centered on each pulley. DO NOT use a cable that
is kinked or starting to unravel.
• Verify the safety pins for the mast lock rod and
mast lock bar are present and secured with a
chain. Check that the spring located in the mast
lock bar is not broken or missing. Check the
operation of the mast lock bar.
• See Figure 4-1. Verify correct mast cable routing.
Preparing for Service
Before servicing the unit, always follow the instructions
listed below.
1. If unit is equipped with the Power Zone controller,
verify the Control Power switch is OFF. Otherwise,
verify the key switch is in the OFF position.
Owner’s Manual for MLT4200IF4 Light Tower 33
Figure 4-1. Power Mast Cable Routing
Page 40
Maintenance
To order go to Discount-Equipment.com
• Verify the wheel lugs are present and properly
tightened. Refer to Towing Safety.
• Check the coolant level daily by inspecting the
level in coolant overflow jug located near the
radiator. Refer to the engine operator’s manual for
coolant recommendations and proper mixture.
Normal operating level is between the ‘full’ and
‘add’ markings on the overflow jug.
•
AFTER ENGINE IS STOPPED AND COMPLETELY
, coolant may be added directly to the coolant
COOL
overflow jug.
•
Check the oil level daily. Refer to the engine
operator’s manual for the appropriate oil specification.
Make sure that the oil is correct for special operating
conditions such as a change in season or climate.
• DO NOT start the unit if the engine oil level is
below the ADD mark on the dipstick.
• Normal operating level is in the cross-hatch
pattern between the full and add markings on
the dipstick.
dd oil only if the oil level is below the add mark
•A
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 r emote star t or t rans fer
switch, verify 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 engine operator’s 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 complete a warranty request.
Use the schedule in the following table as a guide for
regular maintenance intervals. For additional or
replacement copies of the engine operator’s manual,
contact a Generac Mobile Products Authorized Service
Dealer.
Table 4-1. Basic Maintenance Guide
Item Daily
Check Oil Level
Check Coolant Level
Check Fuel Level
Drain Fuel Filter
Check Tire Pressure
Inspect Wheel Bearings
Check All Electrical Connections
Clean Battery
Check Fan Belt Tension (replace if necessary)
Inspect Radiator Fins For Debris; Clean As Required
Preheating Condition Check
Check Engine Starting Conditions and Noise Conditions
Check Exhaust Smoke Condition
Inspect Light Tower Winch For Proper Operation
Replace Engine Oil
Replace Fuel Filter Element
Clean Water Sedimenter Element
Electromagnetic Pump Filter Replacement or Cleaning
Check Fan Belt Tension (replace if necessary)
Oil Filter Element Replacement
Replace Air Filter Element
Lubricate Leveling Jacks
Replace Heated Fuel Filter (if equipped)
Inspect Engine Starting Battery
250
Hours
500
Hours
1000
Hours
34 Owner’s Manual for MLT4200IF4 Light Tower
Page 41
Maintenance
003784
A
B
C
004480
To order go to Discount-Equipment.com
Resetting the Maintenance
Alarms
The PowerZone–DLA will display a warning message
when the unit is due for maintenance or service. The
maintenance or service interval is set at 750 hours of
engine running time. Once the unit has been serviced,
the appropriate maintenance alarm reminder needs to be
reset. The following procedure demonstrates how to
reset the maintenance alarms:
1. With the unit shut down, switch the main circuit
breaker ON (I). After initialization, the controller will
toggle automatically to the Home screen.
2. Press ↑ and ↓ simultaneously to enter the
navigation menu.
3. See Press ↑ or ↓ to move to the top of the
screen. Press to enter the Maintenance screen.
4. Press ↑ or ↓ to highlight the desired alarm that
needs to be reset. Press to start reset.
5. Enter the pin 4444. To do this, press and then ↑
or ↓ to adjust the first number of the maintenance
pin. Press to continue to the next number.
2. Verify the cable and cable attachments are not
damaged. Contact Generac Mobile Products to
order a replacement cable if necessary.
3. Referring to the “Lift / Let Down” decal on the
winch, turn handle according to the specified
direction 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
activated.
Maintenance
The following procedures should be performed at least
annually:
1. See Figure 4-3.The gears and bushings of the
winch must be kept lubricated. Apply a thin film of
grease to the gear teeth (B), and oil the bushings
as needed (C).
2. The ratchet pawl pivot point must be kept
lubricated with a thin oil.
Figure 4-2. Entering Maintenance Pin
Winch Use, Operation and Maintenance
Prior to Use
•
Inspect rope or cable and 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
NOTE: Do not get oil or grease on the friction discs (A).
Figure 4-3. Winch Maintenance
Raising the Lights:
1. The cable must be securely fastened to the object
being lifted and to the winch drum.
Owner’s Manual for MLT4200IF4 Light Tower 35
Page 42
Maintenance
B
B
B
B
B
A
A
A
002306
To order go to Discount-Equipment.com
Jack Maintenance
The following procedures should be performed at least
annually: For side-wind models, the internal gearing and
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
unit at both sides of the tube for side-wind models.
• If equipped, the axle bolt and nut assembly of the
caster wheel must also be lubricated with the same
lightweight oil.
• For top-wind models, apply a lightweight oil to the
screw stem.
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 fitting and pump grease into the fitting until new
grease is visible around the nozzle of the grease gun.
Use only a high quality grease made specifically for
lubrication of wheel bearings. Wipe any excess grease
from the hub with a clean cloth and replace the rubber
plug when finished. The minimum recommended
lubrication is every 12 months or 12,000 miles (19,312
km). More frequent lubrication may be required under
extremely dusty or damp operating conditions.
Figure 4-4. Jack Maintenance
002306
36 Owner’s Manual for MLT4200IF4 Light Tower
Page 43
Section 5: Troubleshooting
(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.
To order go to Discount-Equipment.com
General Troubleshooting
Some of the more common problems are listed in the
table below. This information is intended to be a check or
verification that simple causes can be located and fixed.
It does not cover all types of problems. Refer to the OEM
engine operator’s manual for additional troubleshooting
information. Procedures that require in-depth knowledge
or skills should be referred to a Generac Mobile Products
Authorized Dealer.
Problem Possible Cause Solution
Troubleshooting
Unit cranks, but will not start Fuel level low.
Fuel flow obstructed.
Fuel solenoid inoperable.
Air in fuel system.
Restricted air filter.
Glow plug(s) inoperable.
Unit starts, but stumbles and
dies
High coolant temperature
shutdown
Low oil pressure shutdown Oil level low.
Ambient temperature too
low.
Intake heater inoperable.
Low coolant level.
Blockage in radiator.
Debris on radiator face.
broken coolant pump belt.
cooling fan inoperable.
Oil pump inoperable.
Check fuel level in tank.
Verify fuel pump operation.
Verify fuel solenoid operation.
Bleed air from fuel system.
Inspect air filter for blockage.
Inspect fuel supply hose from tank to fuel filter for cracks and
abrasion.
Check for gelled fuel in fuel system in cold weather, especially at
fuel filter.
Refer to OEM engine operator’s manual for additional
information.
Check if ambient temperature is within unit limits.
Check engine air inlet heater functionality.
Allow engine to cool, then check coolant level in radiator. Add
coolant if needed.
Inspect radiator surroundings for blockage and remove any
foreign matter.
Inspect for visible leaks. Verify tension of water pump drive belt.
Remove load on generator and restart engine. Verify coolant
temperature and shut engine down immediately if it starts to
overheat.
Check oil level. Add oil if necessary.
Unit stalls when export power
is used
The lights are flashing Dusk-to-dawn sensor
If problems persist, contact Generac Mobile Products at 1-800-926-9768 for assistance.
Load exceeds unit rating.
adjustment needed.
Generator frequency too
low.
Turn outlet breaker ON and load sense switch OFF, confirm
generator output is 60hz + or - 2hz. Reapply load.
Adjust the dusk-to-dawn sensor to increase or decrease light
received.
Turn off main breaker.
Check if AC frequency is >40hz.
Owner’s Manual for MLT4200IF4 Light Tower 37
Page 44
Troubleshooting
(000278)
WARNING
Burn hazard. Lamps become extremely hot
while in use. Allow 10–15 minutes for cooling
before handling or lowering mast. Touching a
hot lens or fixture can cause severe burns.
(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 injury.
To order go to Discount-Equipment.com
Troubleshooting the Lights
IMPORTANT NOTE: Only a qualified electrician should
troubleshoot or repair electrical problems occurring in this
equipment. Contact Generac Mobile Products Technical
Service at 1-800-926-9768 for assistance if yo u h ave any
questions, or if problems persist.
Problem Possible Cause Solution
Light fixture is too hot. Allow light to cool 10-15 minutes before restarting.
Faulty lamp connection. Check that the lamp is tight in the socket.
Mast Lights Off,
Checking Outside the
Control Box
Mast Lights Off,
Checking Inside the
Control Box
Mast Lights On But the
Light Output is Low
One or more lights do
not turn on
38 Owner’s Manual for MLT4200IF4 Light Tower
Lamp broken.
Loose lighting
connections.
Damaged or loose
electrical cord.
Loose lighting
connections.
Generator output
incorrect.
Low transformer output.
Fixture and/or lens is
dirty.
Lamp worn due to
normal use.
Damaged or loose
electrical connections.
Generator output
incorrect.
Low transformer output.
Light breaker tripped. Check light breakers.
Lights not turned on.
Check for broken arc tube or outer lamp jacket, broken or loose
components in lamp envelope, or blackening/deposits inside tube.
Check the connections inside the mast junction box and each mast light
housing/socket.
Check the mast electrical cord for damage and check the cord connections
inside the control box.
Check the connections inside the control box and inside each ballast box.
Check the incoming voltage to the ballast by checking 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 and insert the wire probes into the connector blocks for the light
and ground. If proper voltage is not achieved, perform capacitor check to
determine if the capacitor or coil needs to be replaced.
Clean reflective surface inside fixture and both inside and outside surface
of glass lens. Use mild soap and water to clean lens. Other chemicals may
have an adverse effect on the glass.
Replace lamp.
Check the mast coil cord, mast junction box and mast light connections.
Check the incoming voltage to the ballast. Incoming voltage should be
120V +/-5V. If the voltage is incorrect, the engine speed may need to be
adjusted or the 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 240-260V AC. On hard wired mo dels, remo ve the mast junction box cover
and insert the wire probes into the connector blocks for the light and ground.
If proper voltage is not achieved, perform capacitor check to determine if the
capacitor or coil needs to be replaced.
Check electronic control to see if lights are on.
Turn lights on.
Page 45
Section 6: Wiring Diagrams
1
3
2
4
21
43
00175
To order go to Discount-Equipment.com
Mast Junction Box Wiring and Light Connections
Wiring Diagrams
Owner’s Manual for MLT4200IF4 Light Tower 39
Page 46
Wiring Diagrams
To order go to Discount-Equipment.com
AC Wiring
3
WT BK
WT
1
GN
3
BK
2
RD
1
GY
1
CAP 2
4
1
CAP 1
4
GN
GN
4
WTBK
GN
BL
YL OR ORN
GN
2
BK
WT/BK OR BN
WT
GN
BK
RD
BK
WT
MAST CABLE
L1
MAIN
L2
BREAKER
MAIN
CIRCUIT
2
3
2
3
TO RECEPTACLES
BK
BK
BREAKER
BK
RD
BL
BK
RD
GY
BL
BK
RD
BK1
BK2
BK3
BK4
RD4
RD3
BL2
BL1
BK2
GY2
BK
60HZ
50HZ
4
6
7
FF+
3
YL
RD
BL
BK
SE350
BK1
9876543
11
10
YLRDBL
4
YL 14AWG
RELAY
YL 14AWG
COIL
COIL
BK/WT
3
RD 14AWG
RELAY
RD 14AWG
COIL
COIL
BK/WT
2
BL 14AWG
RELAY
COM NO COM NO COM NO
BL 14AWG
COIL
COIL
BK/WT
1
BK 14AWG
RELAY
COM NO
BK 14AWG
COIL
COIL
BK/WT
4 AMP FUSE
ON REGULATOR
VOLTAGE REGULATOR
RD1
RD2
GY1
1
2
TB2
BL
RD
YL OR ORN
TO CNTRL 9
TO CNTRL 8
SEE DC DIAGRAM
TO CNTRL 7
TO CNTRL 6
RD
RDBKRD
100A
RD
WT
L1
L2
N
GN
GEN
F-
F+
BL
BN
BK
BK
RD
BK
RD
BK
RD
WT
GN1
WT/BK OR BN
1
2345678
TB1
RD2
RD1
12
13
14
BK
BAR
TO GND
BAR
TO GND
BAR
TO GND
BAR
TO GND
GN
3
2
1
TRANSFORMERS
GN
3
2
1
GN
3
2
12 43
1
GN2
GN3
GN4
9
10
WT
WT
GN/YL
TO CNTRL 24
TO RECEPTACLES
CIRCUIT BREAKERS
YL
RD
BL
BK
RD 14AWG
RD 14AWG
15A 15A
BK 14AWG
BK 14AWG
15A 15A
1234
90544_C_11.13.14
40 Owner’s Manual for MLT4200IF4 Light Tower
Page 47
AC Wiring—Receptacle Panel
(2x5-20R, 1xTT-30, 1xL14-30R, 2x14-50)
120 VOLT
30 AMP
RV RECPTACLE
20 AMP
CIRCUIT
BREAKER
20 AMP
CIRCUIT
BREAKER
20 AMP
G.F.I
RECEPTACLE
20 AMP
G.F.I
RECEPTACLE
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_07.06.11
To order go to Discount-Equipment.com
Wiring Diagrams
Owner’s Manual for MLT4200IF4 Light Tower 41
Page 48
Wiring Diagrams
Receptacle Panel (2x5-20R, 2xL6-30R, 2xL14-50) 90315_ORG_10.14.11
240 VOLT
30 AMP
TWIST LOCK
RECEPTACLE
20 AMP
CIRCUIT
BREAKER
20 AMP
CIRCUIT
BREAKER
20 AMP
G.F.I
OUTLET
20 AMP
G.F.I
OUTLET
30 AMP
CIRCUIT
BREAKER
30 AMP
CIRCUIT
BREAKER
50 AMP
CIRCUIT
BREAKER
50 AMP
CIRCUIT
BREAKER
TO GROUND
TO NEUTRAL
TO MAIN
BREAKER
RED
BLKBLK
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
50 AMP
TWIST LOCK
RECEPTACLE
Receptacle Panel (2x5-20R, 3xL6-30R, 1xL14-50) 90318_ORG_07.06.11
240 VOLT
30 AMP
TWIST LOCK
RECEPTACLE
20 AMP
CIRCUIT
BREAKER
20 AMP
CIRCUIT
BREAKER
20 AMP
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
BLKBLK
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
RECEPTACLE
Receptacle Panel (2x5-20R, 3xL6-30R, 1xL14-50) 90318_ORG_07.06.11
240 VOLT
30 AMP
TWIST LOCK
RECEPTACLE
20 AMP
CIRCUIT
BREAKER
20 AMP
CIRCUIT
BREAKER
20 AMP
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
BLKBLK
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
RECEPTACLE
To order go to Discount-Equipment.com
AC Wiring—Receptacle Panel Options (1 of 2)
42 Owner’s Manual for MLT4200IF4 Light Tower
Page 49
AC Wiring—Receptacle Panel Options (2 of 2)
Receptacle Panel (2x5-20R, 4xL14-30R)
90321_ORG_07.06.11
20 AMP
CIRCUIT
BREAKER
20 AMP
CIRCUIT
BREAKER
20 AMP
G.F.I
OUTLET
20 AMP
G.F.I
OUTLET
TO GROUND
TO NEUTRAL
TO MAIN
BREAKER
RED
BLKBLK
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 AMP
CIRCUIT
BREAKER
Receptacle Panel (2x5-20R, 2xTT-30, 2x14-50) 90355_ORG_07.06.11
120 VOLT
30 AMP
RV RECPTACLE
120 VOLT
30 AMP
RV RECEPTACLE
20 AMP
CIRCUIT
BREAKER
20 AMP
CIRCUIT
BREAKER
20 AMP
G.F.I
OUTLET
20 AMP
G.F.I
OUTLET
TO GROUND
TO NEUTRAL
TO MAIN
BREAKER
RED
BLKBLK
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
To order go to Discount-Equipment.com
TO GROUND
TO NEUTRAL
TO MAIN
BREAKER
Wiring Diagrams
20 AMP
G.F.I
OUTLET
20 AMP
CIRCUIT
BREAKER
GRN
WHT
RED
RED
20 AMP
G.F.I
OUTLET
GRN
20 AMP
CIRCUIT
BREAKER
BLKBLK
WHT
GRN
WHT
RECEPTACLE
30 AMP
CIRCUIT
BREAKER
240 VOLT
30 AMP
TWIST LOCK
GRN
RED
BLK
RED
BLK
30 AMP
CIRCUIT
BREAKER
RED
BLK
240 VOLT
30 AMP
TWIST LOCK
RECEPTACLE
GRN
WHT
Receptacle Panel (2x5-20R, 3xL14-30R, 1x50A)
RED
BLK
RED
BLK
RECEPTACLE
WHT
RED
30 AMP
CIRCUIT
BREAKER
RED
240 VOLT
30 AMP
TWIST LOCK
GRN GRN
WHT
BLK
50 AMP
CIRCUIT
BREAKER
BLK
240 VOLT
50 AMP
TWIST-LOCK
RECEPTACLE
90320_ORG_07.06.11
RED
BLK
RED
BLK
WHT
Owner’s Manual for MLT4200IF4 Light Tower 43
Page 50
Wiring Diagrams
A
B
POWER + DC
PLUG LOCATION
POWER - DC
1
9 POS PLUG
2
LOWER
INPUT A
30
6 POS PLUG (BINARY INPUTS)
START
4
CONTROL
POWER
SWITCH
RD/BK
BK/WT
4 POS PLUG (GEN VOLTAGE)
PHASE L1 VOLTAGE
PHASE L2 VOLTAGE
PHASE L3 VOLTAGE
21
PLUG LOCATION
NEUTRAL
222324
PHASE L3 CURRENT
PHASE L2 CURRENT
PHASE L1 CURRENT
5 POS PLUG (GEN CURRENT)
PLUG LOCATION
272625
PHASE GND
29
PLUG LOCATION
DSEL401MKII
BK/WT
WTRDBK
GY/OR
RD/YL
BK/WT
TB3
2
1
REMOTE START
CONTACTS
WT
INPUT B
3132333435
INPUT E
INPUT F
INPUT C
6
OUTPUT C
CHARGE ALT
OUTPUT D
8
9
INPUT D
OUTPUT F
7
5
SHIELD
BK
GY
BK
CT-1
CT-3
WT
BK
BK
L3
L1
MAIN
BREAKER
UPPER
UPPER
LOWER
GY
BK/WT
RD
OUTPUT E
FUEL
3
SWITCH INPUTS TO GND
PIN
LOCATION
PIN
LOCATION
PIN
LOCATION
PIN
LOCATION
TO GND
BAR
BAR
TO GND
BAR
TO GND
BAR
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
171819
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
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
BKBLRD
YL
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
TO CB1
TO TB2-14
SEE AC DIAGRAM
TO CB2
TO TB2-13
TO CB3
TO TB2-12
TO CB4
TO TB2-11
TO TB1-6L
SEE AC DIAGRAM
12 V
-+
BATTERY
STARTER
SHIELD NOT CONNECTED
CUT BACK AND TAPE
ALT
RD
TO ENGINE
IGNITION
GLOW LAMP
CAN HI
CAN LO
13
1
3
24
98
31 PIN ISUZU HARNESS
20
IS REG
BLOCK
BK/WT
GY/BK
VI/YL
90545_B_11.14.14
To order go to Discount-Equipment.com
DC Wiring
44 Owner’s Manual for MLT4200IF4 Light Tower
Page 51
DC Wiring for Optional Equipment
To order go to Discount-Equipment.com
BLK
RED
-
+
BATTERY CHARGER
EDISON PLUG
BR
BLU
BRN
YEL/GRN
BL
16/3
12 VOLT 2 AMP CHARGER
GR/YL
BK
RD
BATTERY
CHARGER
68118_A_09.12.14
12 V
BATTERY
HEATED FUEL FILTER
RD/BK
RD/WT
2
R
BK/WT
1
R
R
B
B
STARTER SWITCH
Wiring Diagrams
25A
FUSE
BK
8586
87
ACC
C
NCCOM
87A
RD/VI
SPLICE
BK
TO
GND
BAR
30
RD/BK
NO-
TIME
DELAY
+
TO CNTRL
PANEL START
SOL WIRE
TO
GND
BAR
TO MAIN
BREAKER AUX
SWITCH NC PIN
21
OR/YL1
ESTOP
RD/WT
BK/WT1
TO
GND
BAR
BK
BK
-
+
RPM
SENSOR
WT
BK/WT
12 V
BATTERY
BK/WT2
43
GY
CIRCUIT
BREAKER
RD
OR/YL2
20A
POSITIVE AIR SHUTDOWN 6-20KW
BK/WT
FLOAT
SWITCH
LOW FUEL SHUTDOWN
SOLENOID
PASS
OPT
SW
RPM
PWR
GND
NCCOM
GND
BK1
+
BK
WT
RD
SOL
PNK
TIME
DELAY
PASS
NO-
WT/VI
SPLICE
SPLICE
BATTERY
DISCONNECT
10A
FUSE
ALT CONFIG
65002
MTB PIN 12
INTERIOR LIGHT BATTERY DISCONNECT
10A CIRCUIT BREAKER
CONNECT TO RED WIRE
-
+
LIGHT
10A
FUSE
R
B
2
R
B
1
R
12 V
BATTERY
90574_ORG_09.12.14
LIGHT
ACC
C
STARTER SWITCH
90323_K_06.04.14
Owner’s Manual for MLT4200IF4 Light Tower 45
Page 52
Wiring Diagrams
GN
YL
BN
WT
MARKER
LAMP
AMBER
TRAILER
PLUG
RIGHT
TAIL/TURN
LAMP
LAMP
PLATE
LICENSE
MARKER
LAMP
RED
BK
BK
BK
BK
RD
WT
BK
SPLICE
SPLICE
SPADE
SPADE
LAMP
TAIL/TURN
LEFT
RDWTBK
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
To order go to Discount-Equipment.com
Trailer Lights Wiring
46 Owner’s Manual for MLT4200IF4 Light Tower
Page 53
OIL GRADE: ___________________________________
COOLANT MIXTURE: ________________________ ___
______________________________________________
______________________________________________
______________________________________________
______________________________________________
______________________________________________
______________________________________________
______________________________________________
______________________________________________
______________________________________________
Date
Hours to
Service
Oil Level
Coolant
Level
Service Log
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
To order go to Discount-Equipment.com
Notes
Owner’s Manual for MLT4200IF4 Light Tower 47
Page 54
This page intentionally left blank.
To order go to Discount-Equipment.com
48 Owner’s Manual for MLT4200IF4 Light Tower
Page 55
This page intentionally left blank.
To order go to Discount-Equipment.com
Owner’s Manual for MLT4200IF4 Light Tower 49
Page 56
This page intentionally left blank.
To order go to Discount-Equipment.com
50 Owner’s Manual for MLT4200IF4 Light Tower
Page 57
To order go to Discount-Equipment.com
Page 58
Part No. 37096 Rev. B 3/24/17
To order go to Discount-Equipment.com
©2017 Generac Mobile 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.
Page 59
TO PURCHASE THIS PRODUCT PLEASE CONTACT US
To order go to Discount-Equipment.com
Equipment Financing and
Extended Warranties Available
Discount-Equipment.com is your online resource for
commercial and industrial
561-964-4949
visit us on line @ www.discount-equipment.com
Select an option below to find your Equipment
quality parts and equipment sales.
We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman,
co, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power
May
Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,
Skytrak, Tsurumi, Husquvarna Target, Stow, Wacker, Sakai, Mi-T-M, Sullair, Basic, Dynapac,
MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti, Morrison, Contec,
Buddy, Crown, Edco, Wyco, Bomag, Laymor, EZ Trench, Bil-Jax, F.S. Curtis, Gehl Pavers, Heli,
Honda, 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
Loading...