LIGHT TOWER MLT6SM • MLT6SK • MLT8SK 00749 OPERATING MANUAL Parts manuals available online at www.generacmobile.
WARNING CALIFORNIA PROPOSITION 65 WARNING: Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. WARNING CALIFORNIA PROPOSITION 65 WARNING: This product contains or emits chemicals known to the state of California to cause cancer, birth defects, and other reproductive harm.
Introduction This manual provides information and procedures to safely operate and maintain the Generac Mobile Products unit. For your own safety and protection from physical injury, carefully read, understand, and observe the safety instructions described in this manual. Keep a copy of this manual with the unit at all times. Additional copies are available from Generac Mobile Products, or can be found at www.generacmobile.com.
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Table of Contents Introduction ............................................................................................................................ iii Section 1 - Safety Safety Notes ....................................................................................................................................... 1 Operating Safety................................................................................................................................. 1 Engine Safety ....................
Section 6 - Wiring Diagrams Mast Light Connections .................................................................................................................... 35 AC Wiring - MLT6SM, MLT6SK........................................................................................................ 36 AC Wiring - MLT8SK ........................................................................................................................ 37 DC Wiring - Mitsubishi .........................................
Section 1 - Safety SAFETY NOTES This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. This manual contains DANGERS, WARNINGS, CAUTIONS, NOTICES and NOTES which must be followed to prevent the possibility of improper service, damage to the equipment, personal injury or death.
Safety • Bulbs become extremely hot during use. Allow bulb and light fixture to cool 10-15 minutes before handling. • NEVER raise, lower or turn the mast while the unit is operating. • ALWAYS extend the outriggers and level the unit before raising the mast. DO NOT retract the outriggers while the mast is up. • If for any reason any part of the mast hangs up or winch cable develops slack while raising or lowering the mast, STOP immediately and contact an authorized service representative.
Safety SERVICE SAFETY All service work must be performed by qualified personnel who are familiar with the equipment. Only a qualified electrician should troubleshoot or repair electrical problems occurring in this equipment. Follow the safety guidelines described below to prevent hazardous situations which could result in severe injury or death. • NEVER wash the unit with high pressure hoses, power washers, or steam cleaners. Water may collect in the unit, causing damage to electrical parts.
Safety 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.
Safety SAFETY SYMBOL SUMMARY This equipment has been supplied with numerous safety and operating decals. These decals provide important operating instructions and warn of dangers and hazards. Replace any missing or hard-to-read decals and use care when washing or cleaning the unit. Decal placement and part numbers can be found in the online parts manual at www.generacmobile.com. Below is a summary of the intended meanings for the symbols used on the decals.
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Section 2 - General Information SPECIFICATIONS GENERAC MODEL MLT6SM MLT6SK Engine Make/Brand.............................................................................Mitsubishi ................................Kubota Model ......................................................................................L3E-W461ML ..........................D1005-E3BG1-MGM-1 EPA Tier ..................................................................................4f .............................................
General Information GENERAC MODEL MLT8SK Engine Make/Brand........................................................................................................................... Kubota Model .................................................................................................................................... D1105-E3BG EPA Tier ................................................................................................................................ 4f Horsepower - Prime hp (kW) ...
General Information Unit Dimensions B A C D E 00751 Figure 1 - Unit Dimensions MLT6SM, MLT6SK, MLT8SK A B C D E 118 in. (3 m) 101 in. (2.6m) 23 ft (7 m) 57 in. (1.45 m) 120.5 in. (3.1 m) Specifications are subject to change without notice.
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 COMPONENT LOCATIONS 8 1 7 2 6 5 3 4 01742 Figure 3 - Component Locations - Front and Left Side 1. 2. 3. 4. 17973 G Outriggers Rear Jack Fuel Fill Tie Down Locations 5. 6. 7. 8.
General Information 1 7 6 5 4 2 3 01743 Figure 4 - Component Locations - Rear and Right Side 1. 2. 3. 4. 12 Central lift point Radiator access Forklift pockets Tie down location 5. Control box 6. Rear jack 7.
General Information CONTROL PANEL 1 2 DC CIRCUIT BREAKER AC CIRCUIT BREAKER 12V 120V 3 9 15 SEC. MAX. STOP I I O O I I O O 4 8 3 MAIN BREAKER 240V 7 I O 5 6 00757 Figure 5 - Control Panel Component Locations - MLT6SM, MLT6SK 1. 2. 3. 4. 5. 17973 G DC Breaker AC Breaker Light Switches Electric Winch Switch (Optional) 120V GFCI Receptacle 6. 7. 8. 9.
General Information 1 2 DC CIRCUIT BREAKER AC CIRCUIT BREAKERS 12V 120V 10 3 9 15 SEC. MAX. I 4 STOP O 8 I I O O I I O O 3 MAIN BREAKER 240V 7 I O 5 6 00758 Figure 6 - Control Panel Component Locations - MLT8SK 1. DC Breaker 2. AC Breakers 3. Light Switches 4. Electric Winch Switch (Optional) 5. 120V GFCI Receptacle 14 6. 240V Twist-Lock Receptacle 7. Engine Hour Meter 8. Main Circuit Breaker (For Lights and GFCI Receptacles) 9. Control Power Switch 10.
General Information PRESTART CHECKLIST Before starting the unit, all items in the prestart checklist must be completed. Read and understand ALL safety sections at the beginning of this manual. Ensure all maintenance procedures are up to date. For more information, refer to “General Maintenance” on page 27 and Basic Maintenance Schedules beginning on page 28. The unit must be level with jacks firmly in contact with the ground and wheels lifted approximately 1 inch (2.5 cm) off the ground.
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Section 3 - Operation LIGHT TOWER SET UP 1. For maximum light coverage, locate the unit at ground level or in a spot higher than the area being illuminated by the lamps. WARNING The mast extends up to 23 ft (7 m). Make sure the area above the unit is open and clear of overhead wires and obstructions. Do not set up the unit if high winds or storms capable of producing lightning are expected in the area. DETAIL B C D E DETAIL C A B E 1” F DETAIL E 00843 Figure 7 - Set Up of Outriggers and Jacks 2.
Operation 6. Turn the jack handles clockwise to start leveling the trailer (E). Adjust all three jacks by turning their handles clockwise until they are firmly in contact with the ground and continue until the wheels are approximately 1 inch (2.5 cm) off the ground (F). 7. Before raising the mast, it may be necessary to adjust the lamps. The lamps may be adjusted up, down, left or right by loosening the wing nuts on the trunnion (H) and aiming them in the desired direction.
Operation 4. Rotate the mast by loosening the mast rotation knob at the bottom of the mast (C). Turn the mast until the lights face in the desired direction and then tighten the mast rotation knob to secure the mast in position. WARNING Never raise or lower the mast while the unit is operating. RAISING THE MAST WITH ELECTRIC WINCH OPTION 1. Set up and level the unit. Refer to “Light Tower Set Up” on page 17. WARNING The unit must be leveled with the outriggers extended before raising the mast.
Operation 4. Rotate the mast by loosening the mast rotation knob at the bottom of the mast (D). Turn the mast until the lights face in the desired direction and then tighten the mast rotation knob to secure the mast in position. WARNING Never raise or lower the mast while the unit is operating. STARTING THE UNIT 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. I 5.
Operation 1. Once the engine is up to temperature and running smoothly, switch the main circuit breaker (A) to the ON (I) position. 2. With the main circuit breaker on, switch each individual circuit breaker for the lights (B) to the ON (I) position, one at a time. DC CIRCUIT BREAKER AC CIRCUIT BREAKERS 12V 120V 15 SEC. MAX. I STOP 3. The ballast indicator lights (C) will come on and continue to get brighter as the lights warm up, and then remain on.
Operation CONTROL PANEL RECEPTACLES The control panel is equipped with multiple receptacles for running accessories or tools from the generator. Power is supplied to the receptacles any time the engine is running and the main circuit breaker is switched to the ON (I) position. 240V Twist-Lock Receptacle 120V GFCI Receptacles Note: Do not pull more than 1000W from each receptacle when the lights are on. This will overload the generator and cause the main circuit breaker to trip.
Operation LOWERING THE MAST - MANUAL 1. Shut down the lights and engine, refer to “Shutting Down the Unit” on page 22. Allow the lights to cool 10-15 minutes before lowering the mast. 2. If the unit is going to be moved, it is recommended that the mast is turned so the lights face the rear of the unit. To rotate the mast: a. Loosen the mast rotation knob. b. Rotate the mast until the white arrows are aligned and the metal stop tabs are touching. c. Tighten the mast rotation knob. 3.
Operation 1. Remove the power cables from the two terminals on the winch motor assembly (A). 2. Remove the two flange head screws (B) securing the winch motor assembly to the winch. Retain the screws for reassembly. 3. Carefully remove the motor assembly (C), making sure the two pieces do not separate. 4. Insert a 3/8 in. hex key (D) into the sleeve bearing. 5. Rotate the wrench counter-clockwise to lower the mast. If any slack is observed in the cable, stop immediately and remove the slack. 6.
Operation 10. Maximum recommended speed for highway towing is 45 mph (72 km/h). Recommended off-road towing speed is not to exceed 10 mph (16 km/h) or less, depending on the terrain. LIFTING AND TIE DOWN When lifting the unit, attach any slings, chains or hooks directly to the central lift point. The central lift point is located on top of the enclosure. Note: When using the central lift point, the mast must be in the stowed position, as shown. 1.
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Section 4 - Maintenance 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. It is strongly recommended that the equipment be periodically checked by a Generac Mobile Products Authorized Dealer.
Maintenance overflow jug. • Check the oil level daily. Refer to the engine operator’s manual for the proper viscosity grade of oil, including 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.
Maintenance BASIC MAINTENANCE SCHEDULE - KUBOTA ENGINE 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.
Maintenance 3. Referring to the “Cable In/Cable Out” decal on the winch, turn handle according to the specified direction to lift. The ratchet MUST make a loud clicking sound while pulling line in. Lowering the Lights: 1. Referring to the “Cable In/Cable Out” 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.
Maintenance taken to avoid overheating the mechanical brake. Whine or chatter associated with a new mechanical brake is normal and typically disappears with use. Overheating the mechanical brake may result in permanent damage to, or failure of, the brake. Replace any damaged brake components before resuming use of the winch. JACK MAINTENANCE Apply a lightweight oil to the screw stem annually.
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Section 5 - Troubleshooting TROUBLESHOOTING THE LIGHTS DANGER THIS UNIT USES HIGH VOLTAGE CIRCUITS CAPABLE OF CAUSING SERIOUS INJURY OR DEATH. ONLY A QUALIFIED ELECTRICIAN SHOULD TROUBLESHOOT OR REPAIR ELECTRICAL PROBLEMS OCCURRING IN THIS EQUIPMENT. Mast Lights Off, Checking Outside the Control Box 1. Mast light is too hot. Allow light to cool 10-15 minutes before restarting. 2. Faulty bulb connection. Check that the bulb is tight in the socket. 3. Bulb broken.
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Section 6 - Wiring Diagrams MAST LIGHT CONNECTIONS MAST JUNCTION BOX WIRING 4-LIGHT MAST LIGHT CONNECTIONS 4-LIGHT 2 1 4 3 00768 17973 G MLT6SM/K-8SK Operating Manual 35
G WT BK CB6 15 HOT N GFCI BK BK LOAD WT NC CAP 2 COIL NO 2 3 GN/YL 1 4 1 2 C BK BK RD RD RD BK RD CB1 LIGHT 1 15 LIGHT 2 15 CB2 CB3 LIGHT 3 15 LIGHT 4 15 CB4 RD MAIN CIRCUIT BREAKER BK 30 AMP TWIST GY BL BK RD GY BL BK 1 RD1 WT WT WT BK BK RD RD RD GN/YL GN/YL BK BK1 BL1 BK2 BL2 GY1 T4 BK 1 GN1 GN2 2 3 4 GND STUD T3 BK T2 BK T1 BK BK 1 2 3 GN3 GN4 4 WT/BK OR BN WT BK BL GN RD YL OR ORG GN RD BK 2 BK 3 1 XFMR 2 RD 2
WT WT 10 AWG GFCI GFCI Z RD BK 30 AMP TWIST G Y GN/YL BK RD BK RD RD LOAD G 15 LINE BK BK RD RD COIL LOAD 30 AMP CIRCUIT BREAKER CAP 2 COIL 1 4 1 BK 10 AWG GY BL BK RD GY BL LIGHT 1 15 CB1 LIGHT 2 CB2 15 CB3 LIGHT 3 15 LIGHT 4 15 CB4 RD 10 AWG 40 AMP CIRCUIT BREAKER BK 2 3 2 GN/YL 1 GY2 RD2 RD1 RD GN/YL RD BK BK WT WT RD WT BK1 BL1 BK2 BL2 GY1 BK WT BK T3 T4 BK BK 1 GN1 GN2 2 3 4 GND STUD T2 BK BK T1 BK 1 2 3 GN3 GN4 4 WT
MLT6SM/K-8SK Operating Manual BK/WT VI/YL SPLICE FUEL PUMP VI/YL RED (PULL) 30 RD #2 A SPLICE B #3 A GLOW RELAY RD BL RD GLOW PLUG ENG. GND OIL PRESSURE WARNING SWITCH (N.C.) GY/BL ALT B+ ALT B+ SOLENOID ALTERNATOR OVERHEAT WARNING SWITCH (N.O.) B FUSE BL LINK BLU (COM) 86 WT/YL VI/YL HFF OPT. 87 RD/YL 85 BK/WT FUEL RELAY VI/YL B #1 A BK/WT CONTROL LIGHT SPADE SPADE ENG.
MLT6SM/K-8SK Operating Manual BK/WT A #1 B SPLICE BK/WT SPADE ENG. GND BK/WT CONTROL LIGHT FUEL PUMP BK SPLICE B #2 A HFF OPT. SPLICE ENG. GND 87 BL RD OIL PRESSURE WARNING SWITCH (N.C.) GLOW PLUG 86 BK/YL 30 RD RELAY 85 GY/BL ALTERNATOR OVERHEAT WARNING SWITCH (N.O.) VI/YL VI/YL B #3 SPADE RD RD/YL RD/VI (HOLD) A ALT.
Wiring Diagrams DC WIRING - ELECTRIC WINCH TOP SWITCH (DOWN STOP) BOTTOM SWITCH (UP STOP) SWITCH 1 BN 1 2 3 4 5 6 7 8 9 10 10 BN BL 2 BK BN BN B BK/VI BK/WT C RD/GN BK A BK/VI 11 11 BK/VI DOWN RD/GN 12 12 RD/GN YL YL BL UP 1 WINCH BK 1 2 3 4 5 6 7 8 9 CONTACTOR 1 F1 5A BK RD GN BN BK BK BK YL BK BK YL BL RD BK - + BATTERY 90596_ORG_10.31.
17973 G 65049 RELAY TO OTHER ENGINE COMPONENTS VI/YL VI/YL VI/YL MLT6SM/K-8SK Operating Manual 86 VI/YL BK/ WT L /Y VI RD RD T VI/YL /W RD/WT 87 87a BK/WT 85 CONNECTOR HFF OPT.
42 65049 RELAY TO OTHER ENGINE COMPONENTS VI/YL VI/YL VI/YL MLT6SM/K-8SK Operating Manual 86 VI/YL BK/ WT L /Y VI RD RD T VI/YL /W RD/WT 87 87a BK/WT 85 CONNECTOR HFF OPT.
AMBER L MARKER WT RED LEFT TAIL SPADE RED L MARKER WT BN WT RD BK SPADE SPADE SPADE SPADE SPADE RED LEFT TURN WT BK WT YL BN WT BN WT WT SPLICE WT C WT C B SPADE A A VI/YL BN BN BN WT WT SPLICE TO FUEL CKT BK/WT BN B BN D D WT WT SPADE RING - GND YL SPADE WT SPLICE SPADE BK/WT SPADE SPADE YL BN MLT6SM/K-8SK Operating Manual BK VI/YL GN 17973 G BN WT GN BN BN BN BK BN SPADE WT RD WT WT BK SPADE WT BK RED RIGHT TAIL SPADE RED R MARK
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Section 7 - Options & Accessories LOWER RADIATOR HOSE HEATER OPTION - USE AND MAINTENANCE CAUTION Improper use of the lower radiator hose heater could result in damage to the engine or personal injury. Do not modify the location of the lower radiator hose heater. The following points should be followed when operating a unit equipped with a lower radiator hose heater. • Ensure the cooling system is full of the proper mixture of water and engine coolant before each heater use.
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Service Log OIL GRADE: _____________________________________ BRAND: __________________________________ COOLANT MIXTURE: _____________________________ BRAND: __________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ _______________________________________________
Notes ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ __________________________________________________
