Owner’s Manual Light Tower MLT6SMD 002978 For technical assistance contact: www.generacmobileproducts.
Use this page to record important information about your Light Tower Unit Model Number Unit Serial Number Engine Make Engine Model Number Engine Serial Number Generator Make Generator Model Number Generator Serial Number 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.
Table of Contents Section 1: Introduction and Safety Section 3: Operation Introduction ..........................................................1 Light Tower Setup ............................................. 27 Read This Manual Thoroughly ....................................1 Prestart Checklist .............................................. 28 How to Obtain Service .................................................1 Safety Rules .........................................................
Table of Contents Section 4: Maintenance Section 5: Troubleshooting Emissions Information ......................................37 General Troubleshooting .................................. 43 Daily Walk-Around Inspection ..........................37 General Maintenance .........................................37 Section 6: Wiring Diagrams Preparing for Service ................................................ 37 AC Wiring ...........................................................
Introduction and Safety Section 1: Introduction and Safety Introduction Safety Rules Thank you for purchasing a Generac Mobile Products LLC product. This unit has been designed to provide high performance, efficient operation, and years of use when maintained properly. 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.
Introduction and Safety General Hazards Explosion and Fire Hazards DANGER DANGER Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury. (000103) 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. (000105) WARNING Hearing Loss.
Introduction and Safety Electrical Hazards 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. (000145) DANGER Battery Hazards DANGER Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury. (000188) WARNING Electrocution.
Introduction and Safety Fuel Hazards Operating Safety Positioning the Unit DANGER DANGER (000192) 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. (000260a) DANGER Risk of fire. Allow fuel spills to completely dry before starting engine. Failure to do so will result in death or serious injury. (000174) • DO NOT fill fuel tank near an open flame, while smoking, or while engine is running.
Introduction and Safety Raising and Lowering the Mast 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 > 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. (000297) WARNING Personal Injury. Stop immediately if the mast hangs up or the winch cable develops slack.
Introduction and Safety Towing Safety Reporting Trailer Safety Defects 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.
Introduction and Safety 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. Decal part numbers can be found in the parts manual at www.generacmobile.com.
Introduction and Safety 4 3 NOTICE HINWEIS AVISO AVIS 5 :$51,1* '2 127 retract outriggers with tower up. :$5181* Nicht zurückziehen Ausleger mit Turm auf. 2 $'9(57(1&,$ No retraiga estabilizadores con la torre de arriba. 6 $'9(57,66(0(17 Ne pas retirer les stabilisateurs avec la tour vers le haut.
Introduction and Safety 17 4 16 > 65 mph 18 WARNING ELECTRICAL STORMS & HIGH WIND > 60 mph DO NOT set up unit in winds exceeding 60 mph, or during electrical storms. 15 Nicht bei Windgeschwindigkeit von mehr als 95 km/h oder bei Gewitter aufstellen. Disconnect battery before servicing. Vor der Instandsetzung die Batterieverbindungen lösen. Desconecte la batería antes de realizar el servicio técnico. Débrancher la batterie avant de faire l’entretien.
Introduction and Safety 25 12 12 003583 Figure 1-3.
General Information Section 2: General Information Specifications DESCRIPTION UNITS MLT6SMD Make/Brand — Mitsubishi Model — L3E-W464MLD EPA Tier — Tier 4 Final Horsepower—Prime hp (kW) 10.5 (7.8) Horsepower—Standby hp (kW) 12.2 (9.1) rpm 1200 (ECOSpeed) or 1800 in3 (L) quantity 57.97 (0.95) Fuel Consumption—100% Prime gph (Lph) 0.51 (1.93) Fuel Consumption—75% Prime gph (Lph) 0.38 (1.44) Fuel Consumption—50% Prime gph (Lph) 0.25 (0.
General Information DESCRIPTION UNITS MLT6SMD Lighting Type — Light-Emitting Diode (LED) Driver (4) — Mean Well HLG-240H-30A Lumens — 88,000 amperes 30 Voltage Selection — N/A Voltage Regulation — ARV +/- 6% Voltages Available 1Ø volts 120, 240 Voltages Available 3Ø volts N/A Number of Axles quantity 1 Capacity—Axle Rating lbs (kg) 2200 (998) Tire Size inches 13 — 2 in.
General Information Trailer Tongue Storage and Tow Positions CAUTION Pinching and crushing hazard. To avoid possible injury, keep fingers away from pivot point when folding or unfolding trailer tongue. (000313) The trailer tongue is designed to fold upright for shipping and storage. IMPORTANT NOTE: Do not attempt to tow the unit with trailer tongue in the storage position. 6. Place Trailer Tongue in Tow Position 1. Verify unit is on a level surface and wheels are blocked. See Figure 2-4.
General Information Place Trailer Tongue in Storage Position 1. Verify unit is on a level surface and wheels are blocked. 2. See Figure 2-6. Extend jack (A) enough to allow minimum effort to pivot trailer tongue into storage position. 5. See Figure 2-8. Install pins (B) and (C) at locations shown to secure trailer tongue in storage position. A B C 003591 Figure 2-8. Install Pins and Rotate Jack A B C 6. Remove clevis and remove jack (A) from tongue weldment. 7. Completely retract jack. 8.
General Information Unit Dimensions B A C D E 002983 Figure 2-9. Unit Dimensions MLT6SMD A B C D E 118 in. (3 m) 101 in. (2.6 m) 23 ft. (7 m) 57 in. (1.5 m) 120.5 in. (3.1 m) Specifications are subject to change without notice.
General Information Component Locations G A F E C D B 002984 Figure 2-10. Component Locations—Front and Left Side A. B. C. D. 16 Outrigger and Jack (2) Grounding stud (next to battery) Fuel fill Tie-down locations E. F. G.
General Information J H Q K L P M N M 002985 Figure 2-11. Component Locations—Rear and Right Side H. J. K. L. Central lift point Winch Engine/radiator access (beneath hood) Exhaust pipe Owner’s Manual for MLT6SMD Light Tower M. N. P. Q.
General Information Control Panel A C B D L DC CIRCUIT BREAKER 120VAC OUTLET BREAKER MAST LIGHT CIRCUIT BREAKERS MAST CIRCUIT BREAKER E K CONTROL POWER MAST UP MAST DOWN J LOAD SENSE 240VAC OUTLET BREAKER H F G 002986 Figure 2-4.
General Information Control Panel Features and Functions (K) Mast switch (electric winch units only) (A) DC Circuit Breaker Raises and lowers the mast on units equipped with an electric winch. Resets the DC electrical circuit that powers the control panel and engine components. (L) Control power switch Enables power supply to the PowerZone–DLA. (B) 120VAC outlet breaker Powers the 120V/20A GFCI outlet.
General Information PowerZone–DLA The PowerZone–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. 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 corrected.
General Information Operator Screens Battery Voltage Screen 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. See Figure 2-8. Displays the engine battery voltage. A normal reading is 12-14V on 12 volt systems (with the engine running). 002990 Figure 2-8.
General Information Line Amperage Screen Dusk to Dawn Screen See Figure 2-12. The Line Amperage screen displays the AC output amperage produced by the generator in Amps (A). The load balance for each line (L1 and L3) is displayed in both numerical and graphical form. It is important to maintain a balanced load distribution between lines for optimum generator performance. NOTE: This feature will only work in Auto mode. See Figure 2-12.
General Information Maintenance Screens Home Screen See Figure 2-14. The information displayed on the maintenance screens can be used to identify, diagnose and troubleshoot unit shutdown conditions and poor unit performance.. See Figure 2-15. The Home ( ) screen is the default screen of the controller and displays after the controller has powered up. The controller automatically returns to Home from any other screen after a period of inactivity. .
General Information DTC faults are displayed by the controller. Table 2-1. Possible DTC Faults Maintenance Screen See Figure 2-17. 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. Fault DTC Description Check Engine Fault A fault not recognized by the controller has been detected. Contact the engine manufacturer for support.
General Information About Screen See Figure 2-19. The About ( ) screen contains information about the controller such as the controller’s date and time, the product and USB identification number, and the application and engine version. 08/27/2015 04 22PM Product L401MKII A4 U S B ID 21CFB579D 01970 Figure 2-19.
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Operation Section 3: Operation Light Tower Setup 1. For maximum light coverage, position the unit at ground level or in a spot higher than the area being illuminated by the lamps. DANGER 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. (000260a) NOTE: The mast extends up to 23 ft (7m). DETAIL B C D E DETAIL C E A DETAIL D 1” B F DETAIL E 002987 Figure 3-1. Set Up Outriggers and Jacks 2.
Operation Prestart Checklist Before starting the unit, all items in the prestart checklist must be completed. This checklist applies to both manual and remote starting of the unit. 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. (000100a) Verify all maintenance procedures are up to date. For more information, refer to General Maintenance and Basic Maintenance Schedule.
Operation Raising the Mast—Manual Winch 1. Set up and level the unit. See Light Tower Setup. 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) WARNING High Voltage. DO NOT use the unit if insulation on electrical cord is cut or worn through. Bare wires touching mast or frame can cause electrocution.
Operation Raising the Mast—Electric Winch (If Equipped) 1. Set up and level the unit. See Light Tower Setup. 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) WARNING High Voltage. DO NOT use the unit if insulation on electrical cord is cut or worn through.
Operation Preparing for Start-Up Table 3-1. Engine Speed Selection NOTE: If the engine was run out of fuel or the fuel tank was drained, it may be necessary to bleed the fuel lines before starting. Refer to the engine manual supplied with the unit. Load Sense Switch ON OFF ON Load dependent— variable speed* High speed OFF Low speed Low speed Select Auto Mode or Manual Mode See Figure 3-4. Using the arrows on the PowerZone– DLA, select either AUTO or MANUAL on the Home screen.
Operation 7. Once the engine starts, engine speed will increase to 1800 rpm. The engine may hunt or change speeds until operating speed is reached. After a few minutes at operating speed, the Home screen will display the mode of the unit, the engine status, the engine RPM, and any active program (Scheduler or Dawn to Dusk) in Auto mode. NOTE: The ECOSpeed engine will automatically run at low speed when the lights are turned on.
Operation A Automatic Shutdown B 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. 002535 Figure 3-6. Convenience Outlets See Figure 3-6.
Operation 4. See Figure 3-8. If the unit is going to be moved, rotate the mast so the lights face the rear of the unit.. A 003521 Figure 3-7. Tandem Tow 003275 Telemetry (If Equipped) The digital telemetry option enables the operator to remotely monitor the unit fuel level. A transmitter inside the engine compartment sends real time equipment status information to the user via cellular or satellite connection. Figure 3-8. Stowed (Travel) Position To rotate the mast: a. Loosen the mast rotation knob. b.
Operation Manually Lowering the Mast IMPORTANT NOTE: Do not use this procedure unless it is absolutely necessary. Frequent use of this procedure could damage the motor shaft. 7. 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, tighten the lugs, in the order shown, to the following specifications: 1. See Figure 3-9. Remove the motor cover (A). A 1 4 B 3 2 5 00204 Figure 3-10.
Operation A B 003277 Figure 3-11. Lifting Point • Use the forklift pockets (B) with care. Lift only from the side or the rear. Avoid approaching the unit at an angle, as this can permanently damage the forklift pockets, tires, or cabinet. Verify any obstructions are clear of the forklift tines before lifting.
Maintenance Section 4: 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/fuel leakage, blocked vents, loose/missing hardware, and loose or broken electrical connections.
Maintenance • Normal operating level is in the cross-hatch pattern between the full and add markings on the dipstick. • Add oil only if the oil level is below the add mark 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 remote start or transfer switch, make sure the remote switch is also off and tagged.
Maintenance Resetting the Maintenance Alarms Winch Use, Operation and Maintenance—Manual The Power Zone controller 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.
Maintenance Winch Use, Operation and Maintenance—Electric • Periodically clean and grease the brake assembly. • Keep the winch free of dirt, oil, grease, water and other substances. • Check all mounting bolts and make sure they are tightened to the recommended torque values. Replace any damaged fasteners. • Periodically check all connections to be sure they are tight and free of corrosion.
Maintenance Jack Maintenance Before each use, check each jack foot for damage and remove any mud or debris. The jacks must be clean and in good operating condition to properly support the unit. Trailer Wheel Bearings The trailer axles are equipped with a Zerk grease fitting to allow lubrication of the wheel bearings without the need to disassemble the axle hub. Use only a high quality grease made specifically for lubrication of wheel bearings, such as Valvoline W615 or equivalent. See Figure 4-2.
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Troubleshooting Section 5: Troubleshooting General Troubleshooting WARNING Risk of burns. Allow engine to cool before draining oil or coolant. Failure to do so could result in death or serious injury. (000139) Some of the more common problems are listed in the table below. 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.
Troubleshooting Table 5-1. General Troubleshooting Guide Problem Possible Cause Fuel level low. Solution Check fuel level in tank. Check fuel pump operation. Fuel flow obstructed. Check for gelled fuel in fuel system in cold weather, especially at fuel filter. Unit cranks, but will not start Unit starts, but stumbles and dies Air in fuel system. Bleed air from fuel system. Restricted air filter. Inspect air filter for blockage. Glow plug(s) inoperable.
Wiring Diagrams Section 6: Wiring Diagrams AC Wiring 2 ALL WIRES 14 AWG UNLESS NOTED OR 1 RD 3 4 2 BL 3 GY 4 RD/WT 5 BK/WT VIEW FACING MAST BOX 6 VI 7 BK/YL 2POS WAGO BK RD/WT 2POS WAGO WT BK/WT 2POS WAGO BK RD/YL 2POS WAGO WT 2POS WAGO BK LIGHT #2 LIGHT #3 LIGHT #4 MAST BOX SPLICES BK RD BN GN/YL GN/YL GN/YL BL BN GN/YL 5 POS WAGO OR MENCOM 6 POS CNTRL BOX TO DRIVER CONN 3 GN/YL 4 OR BK BK/BL DRIVER 4 BK DRIVER 3 BN RD 2 RD 6 BL 5 LIGHT #1 WT GN/YL
Wiring Diagrams DC Wiring—Control Box 1 2 3 4 5 6 7 8 9 POWER - DC POWER + DC FUEL START DSEL401MKII CHARGE ALT OUTPUT C OUTPUT D OUTPUT E OUTPUT F BK BL RD OR 11 POS PLUG PLUG LOCATION PIN LOWER LOCATION 10 OUTPUT G 11 OUTPUT H 12 OUTPUT I 13 OUTPUT J 14 ANALOG IN COM ANALOG INPUT A 15 16 ANALOG INPUT B 17 ANALOG INPUT C 18 CAN H CAN L CAN SCREEN TO GND BAR BK/WT 16 RD/BK 16 RD/VI RD/YL OR/WT 16 GY/VI RD/WT 16 10A TO LED RELAY CONTACT POS 1 TO LED RELAY CONTACT POS 2 TO LED RELAY CONTACT POS 3
Owner’s Manual for MLT6SMD Light Tower 12 BN 18 BK/VI 18 1 2 BK/YL 16 BK GLOW PLUGS FUSE LINK 11 10 RD 14 10 SPADE BK VI/YL 16 16 VI/YL 14 FUSE LINK 86 87 30 85 A BK RD VI/YL 16 SPLICE VI/YL 16 FAN FAN CONNECTION B B A WT/BK 16 BL YL RD BK/WT 16 RD 10 85 BK 10 87 30 10 INTAKE HEATER 86 16 GY/RD TWO SPEED ENGINE COOLANT SWITCH 16 BK/WT BK/WT B A C 16 GY/RD RD 10 10 RD RD 16 BK/YL OR/BLK 16 16 RD/YL GY/RD 16 12 OR/YL BK/VI 1.0K 1.1K 3.
Wiring Diagrams DC Wiring - Electric Winch Option TOP SWITCH (DOWN STOP) BOTTOM SWITCH (UP STOP) COM 1 2 3 4 5 6 7 8 9 BN 10 10 BN BK/VI 11 11 BK/VI 12 12 N/O TIME DELAY RELAY SWITCH 1 UP DOWN BL 2 B BN BN BK/VI BK/WT YL YL BL A 1 WINCH BK + BK 1 2 3 4 5 6 7 8 9 N/C CONTACTOR 1 C BK RD GN BN BK BK YL BK BK YL BL RD BK - + BATTERY 90596_A_07.19.
AMBER L MARKER Owner’s Manual for MLT6SMD Light Tower WT WT WT C B VI/YL BN BN BN WT WT SPLICE TO FUEL CKT BK/WT A A BN B BN WT C BK SPADE YL BN WT D D YL WT RED LEFT TURN SPADE SPADE WT BN WT SPADE RD BK SPADE SPADE SPLICE BK/WT WT BK WT VI/YL RED LEFT TAIL RED L MARKER WT BN RING - GND SPADE SPADE SPADE SPADE WT BK BN WT GN BN BN BN BK BN SPADE WT RD WT WT BK SPADE WT BK RED RIGHT TAIL SPADE RED R MARKER BN SPADE SPADE SPADE
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Service Log Section 7: Service Log OIL GRADE:______________________________________ BRAND: __________________________________ COOLANT MIXTURE: ______________________________ BRAND: __________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ ______________________
Part No. 56342 Rev. B 09/14/16 ©2016 Generac Power Systems, Inc. All rights reserved Specifications are subject to change without notice. No reproduction allowed in any form without prior written consent from Generac Power Systems, Inc. Generac Mobile Products 215 Power Drive, Berlin, WI 54923 GeneracMobileProducts.
