Owner’s Manual Light Tower MLT4060MV • MLT4060KV • MLT4080KV SN ____________ and higher 004575 For technical assistance contact: www.generacmobileproducts.
Use this page to record important information about your light tower Unit Model No. Unit Serial No. Engine Model No. Engine Serial No. Generator Model No. Generator Serial 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.
Table of Contents Section 1:Introduction and Safety Light Operation .................................................. 16 Introduction ..........................................................1 Voltage Regulator (If Equipped) ....................... 16 Read This Manual Thoroughly ....................................1 Auxiliary Outlets ................................................ 17 How to Obtain Service .................................................1 Safety Rules .............................
Trailer Lights Wiring ..........................................
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. Read This Manual Thoroughly WARNING Consult Manual.
Introduction and Safety Explosion and Fire Hazards General 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 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 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.
Section 2: General Information Specifications DESCRIPTION Engine Make (Model) UOM MLT4060MV MLT4060KV MLT4080KV — Mitsubishi® (L3E) Diesel, liquid cooled, 4stroke 3 58.1 (0.952) Kubota® (D1005) Diesel, liquid cooled, 4stroke 3 61.08 (1.00) Kubota® (D1105) Diesel, liquid cooled, 4stroke 3 68.53 (1.12) 11.3 (8.4) 12.2 (9.1) 1800 0.59 (2.23) 4 Final 24 12V (1) 440 11.7 (8.7) 13.1 (9.8) 1800 0.67 (2.54) 4 Final 24 12V (1) 440 13.5 (10.1) 15.4 (11.
General Information Unit Dimensions B A C D E 004586 Figure 2-1. Unit Dimensions—MLT4060MV, MLT4060KV, MLT4080KV 8 A B C D E 115 in (2.92 m) 107 in (2.71 m) 25 ft (7.6 m) 68 in (1.73 m) 140 in (3.
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 F E A B C D LEFT SIDE C K G H J I RIGHT SIDE Figure 2-3.
General Information Control Panel—MLT4060MV, MLT4060KV A B C BALLAST INDICATOR LIGHTS MAIN BREAKER 240V D K I ON J I I I ON ON TURN MAIN BREAKER OFF ON O ON O ON O O MAST LIGHT SWITCHES 120V BREAKER OFF GLOW PLUG RUN GLOW PLUG INDICATOR E START 120V F I G 240V DC BREAKER NEUTRAL BONDED TO FRAME H 009003 Figure 2-4. Control Panel (A) Main Circuit Breaker (G) DC Circuit Breaker This 240V (30A) breaker will disconnect power to the lights and auxiliary outlets.
General Information Control Panel - MLT4080KV A B C D BALLAST INDICATOR LIGHTS MAIN BREAKER 240V E L I ON ON TURN MAIN BREAKER OFF K 120V BREAKER I I ON ON O O ON O O MAST LIGHT SWITCHES 120V BREAKER OFF GLOW PLUG 240V BREAKER 120V I ON RUN GLOW PLUG INDICATOR F START I 120V ON ON G O J 240V DC BREAKER H NEUTRAL BONDED TO FRAME 009096 I Figure 2-5.
Section 3: Operation Unit Setup H DETAIL C J F DETAIL D DETAIL G A C D B E DETAIL H G 004591 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 place. Turn the jack handle clockwise to start leveling the trailer. 7. Rotate each jack handle clockwise to start leveling the trailer. Adjust all four jacks by rotating their handles clockwise until they are firmly in contact with the ground (G). 8. 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 the lamps in the desired direction.
Operation 2. See Figure 3-2. Check both sets of mast cables for excessive wear or damage. Verify the cables are properly centered in each pulley (A). Check the electrical cord for damage. the START position, the breaker is closed (switched on) and must be turned OFF (O). 3. Press and hold the winch control toggle switch (B) upward to telescope the mast to the desired height. Extend the mast slowly, verifying the coiled electrical cord is extending at the top sections of the mast.
Operation 2. See Figure 3-7. Switch the main circuit breaker (A) ON (I). 3. Switch the individual circuit breakers for the lights (B) to the ON (I) position, one at a time. OFF GLOW PLUG RUN 4. The ballast indicator lights (C) will turn on and continue to get brighter as the lights warm up, and then remain on. This confirms power is coming from the ballasts to the lights. START A B C BALLAST INDICATOR LIGHTS MAIN BREAKER 240V 003793 I Figure 3-5. Crank Engine ON TURN MAIN BREAKER OFF 4.
Operation the factory. Contact Generac Mobile for additional information before attempting to adjust the voltage regulator. 4%. Also, engine performance decreases about 1% for every 10ºF (5.6ºC) increase in ambient air temperature over 72ºF (22ºC). Auxiliary Outlets Shutting Down the Unit See Figure 3-8. Depending upon the model, the control panel is equipped one or two 120V GFCI (A) and 240V twist-lock (B) outlets for running accessories or tools from the generator.
Operation caught in, or pinched by, the mast while it is being lowered. 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) IMPORTANT NOTE: Contact a GMASD immediately if the mast hangs up or the winch cable develops slack.
Operation mast winch handles or any other obstructions are clear of the forklift tines before lifting. 1 4 3 2 B 5 A 003754 Figure 3-11. 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). 004511 C Figure 3-12. Lifting Point NOTE: After the first road use, re-torque the lug nuts in sequence. 11.
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Section 4: Maintenance Emissions Information 4. 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 Attach a “Do Not Start” sign to the control panel.
Maintenance Figure 4-1. Proper Mast Cable Routing • Check oil level daily. Refer to the engine operator’s • Verify safety pins for the mast lock rod and mast manual for the appropriate oil specification. Verify the oil is correct for special operating conditions such as a change in season or climate. lock bar are present and secured with a chain. Verify the mast lock bar spring is not broken or missing. Check the operation of the mast lock bar.
Maintenance Basic Maintenance Guide (Kubota Engine) ITEM Check oil level Check coolant level Check fuel level Check tire pressure Check all electrical connections Inspect radiator fins for debris, clean as required Inspect light tower winch for proper operation Check fuel pipes and clamp bands Clean air cleaner element Clean fuel filter Check fan belt tightness Drain water separator Check radiator hoses and clamp bands Check intake air line Replace fuel filter cartridge Clean water separator Lubricate leve
Maintenance Winch Preventative Maintenance Schedule Maintenance Activity After First Operation Before Each Use Semi-Annually Check Fasteners Check Electrical Connections Clean And Grease Brake Assembly Check Motor Brushes Visually Check Winch And Control Lower Radiator Hose Heater (If Equipped)—Use and Maintenance The following points should be followed when operating a unit equipped with a lower radiator hose heater.
Section 5: Troubleshooting 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 GMASD. WARNING Risk of burns. Allow engine to cool before draining oil or coolant.
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 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. (000278) Electrocution.
Section 6: Wiring Diagrams Mast Junction Box Wiring and Light Connections 2 1 4 3 00768 Owner’s Manual for Mobile Light Tower 27
TO GND BAR TO GND BAR WT GN N 10 9 8 7 6 5 4 3 2 1 WT WT WT WT WT WT WT RD BK RD BK RD GFCI GFCI BK X Y GN WT 8KW UNITS ONLY 20A CB5 20A CB6 30A 15 A BK 15 A GEN TO GND BAR TO GND BAR Z G GN TO GND BAR BK RD BK RD 12 11 10 9 8 7 6 5 4 3 2 1 YL BK BL RD RD RD RD RD RD GY RD GY YL BL WT RD BK BK BK BK BK BL BK BL BK LED BOARD CAP 2 MAST CABLE 4 3 2 1 . 1 2 . 3 CAP 1 TRANSFORMER 1 RD RD CB7 GY RD BK BL BK RD YL . 2 .
Wiring Diagrams DC Wiring—Mitsubishi 10000044660_B_02.07.
"TURN MAIN BREAKER OFF" WARNING LIGHT RD/VI BK BK/WT BK/YL ALTERNATOR OR/YL RD/YL MAIN BREAKER AUX SWITCH GLOW PLUGS RD/VI (HOLD) VI/YL RD/YL BK 30 STARTER RD RD/WT N/C N/O 12V BATTERY RD/VI RD RD/VI TIME DELAY RELAY - + COM STARTER SWITCH BK/YL BK VI/YL GY/VI GY/BL 10 AMP CIRCUIT BREAKER OVERHEAT WARNING SWITCH (N.O.) YL VI/YL BK RD OIL PRESSURE WARNING SWITCH (N.C.) FUEL PUMP HOUR BK/WT SOLENOID (PULL) Wiring Diagrams DC Wiring—Kubota 90339_E_01.30.
Wiring Diagrams DC Wiring—Electric Winch Owner’s Manual for Mobile Light Tower 31
Wiring Diagrams DC Wiring for Optional Equipment 32 Owner’s Manual for Mobile Light Tower
Owner’s Manual for Mobile Light Tower LEFT TAIL/TURN LAMP RED MARKER LAMP AMBER MARKER LAMP BK BK BK BK WT BK RD WT SPLICE SPLICE SPADE SPADE SPADE BN WT WT BN SPADE SPADE LICENSE PLATE LAMP BK YL WT BN BN TRAILER PLUG GN RING WT SPLICE SPADE SPADE BN WT BK RD WT SPLICE SPLICE BK BK BK BK RIGHT TAIL/TURN LAMP RED MARKER LAMP AMBER MARKER LAMP Wiring Diagrams Trailer Lights Wiring WT BN YL GN 90341_B_12.20.
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Part No. 33298 Rev. F 01/14/2020 ©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.
