Generac Power Systems MAGNUM MLT4200IF4V Bedienungsanleitung

Owner’s Manual

Light Tower

MLT4200IVF4

SAVE THIS MANUAL FOR FUTURE REFERENCE

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ii Owner’s Manual for MLT4200IVF4 Light Tower

Use this page to record important information about your Light Tower

Record the information found on your unit data label on

this page. See unit serial number location (Unit Serial

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 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.

Unit Model Number

Unit Serial Number

Engine Model

Number

Engine Serial

Number

Generator Model

Number

Generator Serial

Number

(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.

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Owner’s Manual for MLT4200IVF4 Light Tower iii

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

Section 2: General Information

Specifications ......................................................7

Unit Dimensions ..................................................8

Unit Serial Number Locations ............................9

Component Locations .......................................10

Control Panel .....................................................11

Power Zone–DLA ...............................................12

Controller Features and Functions ............................12

Operator Screens ......................................................13

Section 3: Operation

Light Tower Setup .............................................17

Prestart Checklist ..............................................18

Raising the Mast ................................................18

Preparing for Start-Up .......................................19

Select AUTO or MANUAL Mode ...............................19

Configure for Intended Use .......................................19

Emergency Stop Switch ...................................19

Engine Break-In Requirements ........................20

Manually Starting the Unit ................................20

Auto (Remote) Starting of the Unit ..................20

Light Operation ..................................................21

Engine Derating .................................................21

Wet Stacking ......................................................21

Voltage Regulation ............................................21

Customer Convenience Outlets .......................21

Remote Start Terminal Block ...........................22

Transfer Switch .................................................22

AUTO Exercise Timer ........................................23

Shutting Down the Unit .....................................25

Automatic Shutdown .................................................25

Lower Radiator Hose Heater (If Equipped) .....25

Use and Maintenance ...............................................25

Lowering the Mast .............................................25

Lowering the Mast—Manually ..................................26

Towing the Unit .................................................26

Lifting the Unit ...................................................27

Section 4: Maintenance

Emissions Information ......................................29

Daily Walk-Around Inspection .........................29

General Maintenance ........................................29

Preparing for Service .................................................29

Cleaning the Unit .......................................................29

Inspecting the Unit .....................................................29

Basic Maintenance Schedule ...........................30

Resetting the Maintenance Alarms ..................32

Winch Use, Operation and Maintenance .........32

Winch Mechanical Brake ...........................................32

Jack Maintenance ..............................................33

Trailer Wheel Bearings .....................................33

Table of Contents

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Table of Contents

iv Owner’s Manual for MLT4200IVF4 Light Tower

Section 5: Troubleshooting

General Troubleshooting ..................................35

Troubleshooting the Lights ..............................36

Section 6: Wiring Diagrams

Mast Junction Box Wiring and Light

Connections .......................................................37

AC Wiring ..........................................................38

AC Wiring—Receptacle Panel ..........................39

AC Wiring—Receptacle Panel

Options (1 of 2) ..................................................40

AC Wiring—Receptacle Panel

Options (2 of 2) ..................................................41

DC Wiring ...........................................................42

DC Wiring for Electric Winch ............................43

DC Wiring for Optional Equipment ..................44

Trailer Lights Wiring ..........................................45

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Safety Rules & General Information

Owner’s Manual for MLT4200IVF4 Light Tower 1

Section 1: Safety Rules & General Information

Introduction

Thankyou for purchasing a Generac MobileProductsLLC

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

manufacturerreservestherighttomaketechnicalupdates,

corrections, and product revisions at any time without

notice.

Read This Manual Thoroughly

The owner is responsible for proper maintenance and safe

use of the equipment. Comply with regulations the

Occupational Safety and Health Administration (OSHA)

has established, or with equivalent standards. Also, verify

thattheunitis applied,used,andmaintainedinaccordance

withthemanufacturer'sinstructionsandrecommendations.

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 that should be

followed during setup, operation and maintenance of the

unit and battery. ALWAYS supply this manual to any

individual that will use this machine.

Safety Rules

The manufacturer cannot anticipate every possible

circumstance that might involvea hazard. Thewarnings in

this manual, and on tags and decals affixed to theunit are,

therefore, not all inclusive. If using a procedure, work

methodoroperatingtechniquethatthemanufacturerdoes

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.

Throughoutthispublication,andontagsanddecalsaffixed

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:

NOTE: Notes contain additional information important to

a procedure and will be found within the regular text of

this manual.

These safety alerts cannot eliminatethe hazards that they

indicate. Common sense and strict compliance with the

special instructions while performing the action or service

are essential to preventing accidents.

(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.

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Safety Rules & General Information

2Owner’s Manual for MLT4200IVF4 Light Tower

General Hazards Explosion and Fire Hazards

Trailer Hazards

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)

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Safety Rules & General Information

Owner’s Manual for MLT4200IVF4 Light Tower 3

Electrical Hazards Battery Hazards

Alwaysrecyclebatteriesinaccordancewithlocallawsand

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

(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)

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Safety Rules & General Information

4Owner’s Manual for MLT4200IVF4 Light Tower

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

suppliedwiththeunitwhenitwas shippedfromthefactory.

•DO NOT run engine indoors or in an area with poor

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).

Operating Safety

Positioning the Unit

•The area immediately surrounding the unit should

be dry, clean, and free of debris.

•Position and operate the unit on a firm, level

surface.

•If the unit is equipped with a frame grounding stud,

follow the National Electrical Code (NEC), state,

and local regulations when connecting.

Starting the Unit

(000192)

DANGER

Explosion and fire.Fuel and vapors are 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

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Safety Rules & General Information

Owner’s Manual for MLT4200IVF4 Light Tower 5

Raising and Lowering the Mast

•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 25 ft (7.6 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.

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.

DO NOT

perform even routine

service (oil/filter changes, cleaning, etc.) unless all

electrical components are shut down.

•

ALWAYS

use extreme caution when servicing this

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

wash the unit with high pressure hoses,

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.

•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 equipment.

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

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.

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