Owner’s Manual Light Tower MLTS SN ____________ and higher 010568 For technical assistance contact: www.generacmobileproducts.
Use this page to record important information about your unit Unit Model No. 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. Unit Serial No. Engine and generator serial numbers are located on separate data plates affixed to the engine and generator. Engine Model No.
Table of Contents Section 1:Introduction and Safety Introduction ..........................................................1 Power Zone Autolight Controller (If Equipped) ...................................................... 19 Read This Manual Thoroughly ....................................1 About UTILITY Mode (If Equipped) .................. 21 Safety Rules .........................................................1 About SLEEP Mode (If Equipped) .................... 21 How to Obtain Service .......
Load Limit and Overload ........................................... 36 Removing Loads from Receptacles (If Equipped) .......................................................36 Storing the Unit ..................................................36 Lowering Mast—Manual Winch ........................36 Section 5: Troubleshooting General Troubleshooting .................................. 45 Troubleshooting the Lights .............................. 46 Troubleshooting Controller Fault Indicators .................
Section 1: Introduction and Safety Introduction Thank you for purchasing a Generac Mobile 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 updates, corrections, and product revisions at any time without notice.
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 WARNING Hearing Loss.
Introduction and Safety Electrical Hazards Battery Hazards DANGER 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 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 DANGER Positioning the Unit 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. (000192) DANGER Risk of fire. Allow fuel spills to completely dry before starting engine. Failure to do so will result in death or serious injury. DANGER High Voltage.
Introduction and Safety Raising and Lowering the Mast Service Safety 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 or equipment damage.
Introduction and Safety • Connect safety chains in a crossing pattern under the tongue. • Before towing the trailer, verify that 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. Running Lights Verify directional and brake lights on the trailer are connected and working properly. Wheels and Tires • Inspect trailer tires for wear and proper inflation.
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. ID Description 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.generacmobileproducts.com.
Introduction and Safety 1 0°± 5° 1 Inch (25 mm) 10000035325 2 0°± 5° 1 Inch (25 mm) 008626 10000035402 Figure 1-1.
Introduction and Safety DANGER 7 OVERHEAD POWER LINES 8 Contact with overhead electrical power lines will cause serious injury or death. Do not position light tower under electrical power lines. 3 GEFAHR Der kontakt mit elektrischen Hochspannungsleitungen kann zu schweren oder lebensgefährlichen Verletzungen führen. Den Beleuchtungswagen nie direkt unter Hochspannungsleitungen aufstellen. 9 PELIGRO El contacto con las líneas electricas elevadas podría causar lesiones serias o la muerte.
Introduction and Safety 6 20 NOTICE HINWEIS AVISO AVIS 14 23 :$51,1* '2 127 retract outriggers with tower up. :$5181* Nicht zurückziehen Ausleger mit Turm auf. 21 $'9(57(1&,$ No retraiga estabilizadores con la torre de arriba. $'9(57,66(0(17 Ne pas retirer les stabilisateurs avec la tour vers le haut.
Section 2: General Information Specifications Description Engine Make (Model) EPA Certification Fuel Consumption—Lights Only Battery—Group Number Battery—Voltage (Qty. Per Unit) Battery—Rating Capacities Fuel Tank Volume Usable Fuel Volume Coolant (Incl. Engine) Oil (Incl. Filter) Maximum Run Time (Lights Only) Generator Make (Model) Unit of Measure Standard Unit Export Power Option — Tier gph (Lph) — VDC (qty) CCA Mitsubishi® (L2E) 4 Final 0.25 (0.95) 24 12 (1) 440 Mitsubishi® (L2E) 4 Final 0.24 (0.
General Information Unit Dimensions B A C D E 009807 Figure 2-1. Unit Dimensions 12 A B C D E 118 in (3 m) 101 in (2.6 m) 23 ft (7 m) 10 ft (3.05 m) 57 in (1.
General Information Unit Serial Number Locations Refer to the illustration to locate the unit ID tag and Vehicle Identification Number (VIN) tag on the unit. Important information, such as the unit serial number, model number, VIN, and tire loading information are found on these tags. Record the information from these tags so it is available if the tags are lost or damaged. When ordering parts or requesting assistance, you may be asked to provide this information.
General Information Trailer Tongue Storage and Tow Positions 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. CAUTION Pinching and crushing hazard. To avoid possible injury, keep fingers away from pivot point when folding or unfolding trailer tongue. (000313) 6. See Figure 2-5. Using both hands, slowly lower trailer tongue into tow position. Place Trailer Tongue in Tow Position 1.
General Information Place Trailer Tongue in Storage Position 1. Verify unit is on a level surface and wheels are blocked. 2. See Figure 2-7. Extend jack (A) enough to allow minimum effort to pivot trailer tongue into storage position. A C B 003591 Figure 2-9. Install Pins and Rotate Jack A B 6. Remove clevis and remove jack (A) from tongue weldment. C 7. Completely retract jack. 003593 Figure 2-7. Extend Jack and Remove Pins 8.
General Information Component Locations A B I H C G J D E E F R Q K P O 010573 N L M Figure 2-10.
General Information Control Panel Standard Analog A B Analog with Import Power (If Equipped) C A D B C D M E F E J L G F H I I G K H J 010574 010575 Figure 2-11. Standard Analog Controls Figure 2-12.
General Information Power Zone with Import Power (If Equipped) Power Zone® (If Equipped) A B A C B C D E D F J E G H F G I H 010576 Figure 2-13.
General Information Power Zone Autolight Controller (If Equipped) See Figure 2-15. The Power Zone Autolight controller monitors vital unit functions, and indicates operational status and fault conditions. The controller can be set to automatic (AUTO) mode, in which the lights and engine automatically start and stop according to input from the dusk-to-dawn sensor. B A C 010578 E D Figure 2-15.
General Information (A) Light Fixture ON-OFF Button (4 locations) (C) UTILITY Mode Button See Figure 2-16. These buttons control power to the light fixtures. One button controls one light fixture, as illustrated. NOTE: This button only functions in units equipped with UTILITY mode. A See Figure 2-18. This button controls UTILITY mode. Press the button to switch UTILITY mode ON or OFF. A Light 1 Light 2 010581 Figure 2-18. UTILITY Mode button Light 3 Light 4 010579 Figure 2-16.
General Information About UTILITY Mode (If Equipped) Units equipped with UTILITY mode can provide lighting and 120 V power without running the genset. Requirements for UTILITY mode are: • Utility power supply • 240 V, four-terminal cord NOTE: In UTILITY mode, the engine does start. About SLEEP Mode (If Equipped) Units equipped with Power Zone controls are also equipped with SLEEP mode.
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Section 3: Operation Unit Setup DETAIL D C D DETAIL E E F DETAIL F B A 1” G DETAIL G 010584 Figure 3-1. Setup Components 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 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) 1.
Operation 7. Before raising the mast, it may be necessary to adjust the lamps. The lamps may be adjusted up, down, left or right by simply aiming them in the desired direction. the second mast section is visible as seen in Detail D. Raising the Mast—Manual Winch 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) A WARNING STOP Tipping hazard. Extend the outriggers and level the unit before raising the mast.
Operation Raising the Mast—Electric Winch (If Equipped) 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) 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) DETAIL B WARNING Tipping hazard.
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 6. See Figure 3-7. Turn ignition switch to GLOW PLUG position and hold for 10 to 15 seconds 9. Begin using lights and receptacles (if equipped), in accordance with the following: • To operate lights, see Operating Lights—Analog Controls. • To operate 120 V convenience receptacles, see Customer Equipped). Convenience Receptacles (If Starting Unit—Power Zone Controls (MANUAL Mode) 009951 Figure 3-7.
Operation NOTE: The LEDs (A, B, C) allow the operator to monitor start-up progression. See table below. A Illuminates when START-STOP button is pushed. Remains illuminated during start-up process and while engine is running. B Flashes when glow plugs are active. C Illuminates when engine cranks. See Figure 3-15. Three schedules are available. The active schedule is indicated by an illuminated LED on the AUTO mode button. A 6.
Operation Operating Lights—Analog Controls NOTE: If the main circuit breaker is OFF, the light fixture ON-OFF button LED (A) illuminates but the light fixture does not. Switch main circuit breaker ON. 1. Verify the unit is ON and running smoothly. See Starting Unit—Analog Controls. A 2. See Figure 3-16. Switch main circuit breaker to ON (I). MAIN AC CIRCUIT BREAKER 010591 Figure 3-19. Light Fixture ON-OFF Button 010589 Figure 3-16.
Operation Shutting Down Unit—Analog Controls Shutting Down Unit—Power Zone Controls (MANUAL Mode) 1. Stop using and unplug equipment from the 120 V convenience receptacles. See Removing Loads from Receptacles (If Equipped). 2. See Figure 3-20. Switch lights to OFF (O). 010586 1. Remove all loads from receptacles. See Removing Loads from Receptacles (If Equipped). 2. See Figure 3-24. Switch OFF (O) lights by pressing the light ON-OFF buttons. Light 1 Light 2 Light 4 Light 3 Figure 3-20.
Operation Shutting Down Unit—Power Zone Controls (AUTO Mode) NOTE: To skip cool-down cycle, press the ENGINE START-STOP button twice. NOTE: In AUTO mode, the unit automatically shuts down, in accordance with the active schedule. 4. See Figure 3-32. Switch controller power switch to OFF (O). IMPORTANT NOTE: This procedure cancels AUTO mode and shuts down the unit. 1. Remove all loads from receptacles. See Removing Loads from Receptacles (If Equipped). 2. See Figure 3-38.
Operation 8. See Figure 3-37. Switch main circuit breaker to ON (I). Starting Utility Mode (If Equipped)—Analog Controls MAIN AC CIRCUIT BREAKER 1. Shut down the unit (if applicable). 2. Open unit hood. 3. See Figure 3-33. Switch the flex switch (if equipped) to position 0. 010589 Figure 3-37. Main AC Circuit Breaker ON (I) 9. See Figure 3-38. Switch lights to ON (I). 010595 Figure 3-33. Flex Switch—Position 0 4. See Figure 3-34. Switch main AC circuit breaker to OFF (O).
Operation 5. See Figure 3-41. Switch controller power to OFF (O). NOTE: When utility mode is activated, the LED (A) switches on. 11. See Figure 3-46. Switch main circuit breaker to ON (I). MAIN AC CIRCUIT BREAKER 010596 Figure 3-41. Controller Power OFF (O) 6. See Figure 3-42. Install 240 V, four-terminal cord to unit power inlet port. 010589 Figure 3-46. Main AC Circuit Breaker ON (I) 12. See Figure 3-47. Switch lights ON (I) by pressing the light ON-OFF buttons.
Operation 4. See Figure 3-49. Switch main AC circuit breaker to OFF (O). 3. See Figure 3-52. Switch lights OFF (O) by pressing the light ON-OFF buttons. MAIN AC CIRCUIT BREAKER 010587 Figure 3-49. Main AC Circuit Breaker OFF (O) Light 1 Light 2 Light 4 Light 3 010579 5. See Figure 3-50. Switch the flex switch (if equipped) to position 0. Figure 3-52. Light Fixture ON-OFF Buttons 4. See Figure 3-53. Switch main AC circuit breaker to OFF (O). MAIN AC CIRCUIT BREAKER 010595 Figure 3-50.
Operation 7. See Figure 3-56. Switch the flex switch (if equipped) to position 0. Dusk-to-Dawn Sensor (If Equipped) See Figure 3-58. Units equipped with Power Zone Autolight controller are also equipped with a dusk-todawn sensor (A), which senses light and accordingly starts and stops the unit. 010595 Figure 3-56. Flex Switch—Position 0 The sensor’s perception of dusk and dawn can be adjusted, due to an adjustable light-shield equipped near the sensor. 8. See Figure 3-57.
Operation Customer Convenience Receptacles (If Equipped) Lowering the Mast—Manual Winch 1. Shut down the lights and engine. See Shutting Down Unit—Analog Controls. See Figure 3-59. The unit may be equipped with a 120V, 20 A, GFCI, duplex receptacle; for powering accessories or tools. 2. Lower the mast. 3. Use the winch handles 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. . 010601 Figure 3-59.
Operation Lowering the Mast—Electric Winch (If Equipped) 1. See Figure 3-61. Remove the motor cover (A). A NOTE: On key switch models, key must be in RUN to operate electric winch. B 1. Press and hold the upper winch control switch downward 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. 2. Shut down the engine. See Shutting Down Unit— Analog Controls. 3.
Operation Test the PAS at least once a month to ensure optimal valve performance. There are two methods: 1. Pull the T-handle. (NOTE: The valve must be open before testing.) 2. Press the emergency stop button. Tandem Tow (If Equipped) See Figure 3-63. The tandem tow hitch option (A) allows the operator to tow a second MLTS Light Tower in series behind the unit equipped with the hitch. Testing the PAS triggers an actuator, closing the butterfly valve inside the valve body.
Operation 1 4 3 2 5 A 003754 Figure 3-65. Tightening Wheel Lugs Figure 3-64. Heated Fuel Filter a. Start all lug nuts by hand. Towing the Unit Once the engine is shut down and the mast and lights are correctly stowed, proceed as follows to prepare the unit for towing. 1. 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.
Operation Lifting the Unit Tying Down the Unit Proceed as follows to prepare the unit for lifting: When securing the unit for transportation, verify the equipment being used to fasten the unit is in good condition and has sufficient strength to hold the unit in place during transport. 1. Verify the equipment being used to lift the unit is in good condition and has sufficient capacity. For approximate weights, refer to Specifications. See Figure 3-67. Use the tie-down points (C) as shown. 2.
Section 4: Maintenance Emissions Information 3. Disconnect the negative (–) terminal on the battery. For warranty information, please refer to the diesel engine manual supplied with this unit. 4. Attach a “Do Not Start” sign to the control panel to signify that the unit is being serviced and reduce the chance of unauthorized use. Daily Walk-Around Inspection Cleaning the Unit CAUTION CAUTION Equipment Damage. Failure to perform a daily inspection could result in damage to the unit.
Maintenance • 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. • 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. • Check the fuel level. • If the unit is connected to a remote start or transfer switch, verify the remote switch is off and tagged.
Maintenance Manual Winch: Use, Operation, and Maintenance Prior to Use • Inspect rope or cable and replace if damaged. • Inspect mounting hardware for correct tightness and torque if necessary. • Gears, ratchet pivot point, and shaft bushings must be kept lubricated with a thin film of oil or grease. Operation Raising the Lights: Failure to replace a damaged cable could result in breakage. • Regularly inspect the brake for slippage or drift. This is detected visually when winch is under load.
Maintenance Winch Preventative Maintenance Schedule After First Operation Maintenance Activity Before Each Use Semi-Annually Inspect fasteners Inspect electrical connections Clean and grease brake assembly Inspect motor brushes Inspect winch and control Trailer Wheel Bearings Jack Maintenance 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.
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 Troubleshooting the Lights Only a qualified electrician should troubleshoot or repair electrical problems occurring in this equipment. Contact Generac Mobile Technical Service at 1-800-926-9768 for assistance if you have any questions, or if problems persist. 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.
Troubleshooting Troubleshooting Controller Fault Indicators See Figure 5-1. When a fault occurs, the engine shuts off and an LED indicator illuminates on the controller. C B A 010580 Figure 5-1. Fault Indicator Button Illuminated Indicates Fault LED Resolution A Low engine oil pressure or See General Troubleshooting —low oil pressure & high engine high engine coolant temperature coolant temperature. A+C Engine overspeed or engine underspeed C Fail to crank (AUTO mode only) B+C Loss of speed 1.
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Section 6: Wiring Diagrams Mast Junction Box Wiring and Light Connections 010606 Owner’s Manual for Mobile Light Tower 49
Wiring Diagrams AC Wiring (1 of 3) 3 CH-GRND MCB GEN CON TSW 2 TB 2 1 5 4 3 7 6 CCC CGS 5 LT2 7 2 LT1 4 LT4 *VIEW FACING LIGHTS* 6 1 LT3 3 JB5A LT1 JB2A JB2C JB2D LT3 JB5B LT4 **STANDARD** LT2 JB2B JBX A0000116053SH1_B_11.05.
Wiring Diagrams AC Wiring (2 of 3) 3 RCB 20A GFCI CH-GRND ACB 15A MCB GBTB TB 2 TSW 2 1 5 4 3 7 6 CGS CCC LT1 LT4 LT2 *VIEW FACING LIGHTS* LT3 1 2 3 4 5 6 7 JB5A LT1 JB2A LT2 JB2B JB2C LT3 JB5B LT4 **EXPORT** JB2D JBX A0000116053SH2_B_11.05.
Wiring Diagrams AC Wiring (3 of 3) RCB 20A GBTB TSW CGS CCC LT1 LT2 LT4 *VIEW FACING LIGHTS* LT1 LT2 LT3 JB2D LT3 1 2 3 4 5 6 7 JB2B ACB 15A MCB 2 2 1 5 4 3 7 6 3 JB5A JB2C JB5B LT4 JBX **EXPORT WITH INPUT POWER ** JB2A Owner’s Manual for Mobile Light Tower 52 INPUT SWITCH INPUT POWER PLUG L14-20P GFCI CH-GRND A0000116053SH3_B_11.05.
Wiring Diagrams DC Wiring A0000116053SH1_B_11.05.
Wiring Diagrams AC Wiring—Power Zone (If Equipped) (1 of 3) A0000221210SH1_B_11.05.
Wiring Diagrams AC Wiring—Power Zone (If Equipped) (2 of 3) A0000221210SH2_B_11.05.
Wiring Diagrams AC Wiring—Power Zone (If Equipped) (3 of 3) A0000221210SH3_B_11.05.
Wiring Diagrams DC Wiring—Power Zone (If Equipped) A0000221208SH1_B_11.05.
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Part No. A0000389937 Rev A 01/24/2020 ©2020 Generac Mobile Products, LLC All rights reserved. Specifications are subject to change without notice. No reproduction allowed in any form without prior written consent from Generac Mobile Products, LLC. Generac Mobile Products, LLC 215 Power Drive, Berlin, WI 54923 GeneracMobileProducts.
