GENERAC MLT5080K, MLT5080M, MLT3060MV, MLT3060KV, MLT4060K Owner's Manual
...
Owner’s Manual
Discount-Equipment.com
Light Tower
MLT5060M • MLT5060K
MLT5080M • MLT5080K • MLT5080KCAN
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Use this page to record important information about your Light Tower
(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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Record the information found on your unit data label on
Unit Model Number
Unit Serial Number
Engine Model
Number
Engine Serial
Number
Generator Model
Number
Generator Serial
Number
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 an 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
or 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.
ii Owner’s Manual for MLT Light Tower
Table of Contents
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Section 1: Introduction and Safety
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 ..................................................9
Unit Serial Number Locations ..........................10
Component Locations .......................................11
Control Panel - MLT5060M, MLT5060K ............12
Control Panel Features and Functions ......................13
Control Panel - MLT5080M, MLT5080K,
MLT5080KCan ....................................................14
Control Panel Features and Functions ......................15
Starting the Unit ................................................ 19
Automatic Shutdown ........................................ 20
Light Operation .................................................. 20
Auxiliary Outlets ................................................ 21
Wet Stacking ...................................................... 21
Voltage Regulator Option ................................. 21
Engine Derating ................................................. 21
Shutting Down the Unit ..................................... 21
Lowering the Mast ............................................. 22
Removing the Lights for Transportation ......... 22
Towing the Unit .................................................22
Lifting the Unit ................................................... 23
Section 4:Maintenance
Emissions Information ...................................... 25
Daily Walk-Around Inspection ......................... 25
General Maintenance ........................................ 25
Preparing for Service .................................................25
Cleaning the Unit ....................................................... 25
Inspecting the Unit .....................................................25
Basic Maintenance Schedule ........................... 26
Winch Use, Operation and Maintenance ......... 28
Prior to Use ............................................................... 28
Operation ...................................................................28
Maintenance ..............................................................28
Optional Lower Radiator Hose Heater Use and
Maintenance ....................................................... 28
Trailer Wheel Bearings ..................................... 29
Jack Maintenance .............................................. 29
Section 5:Troubleshooting
General Troubleshooting .................................. 31
Troubleshooting the Lights .............................. 32
Section 3:Operation
Light Tower Setup .............................................17
Prestart Checklist ..............................................18
Raising the Mast ................................................18
Owner’s Manual for MLT Light Tower 1
Section 6:Wiring Diagrams
Mast Junction Box Wiring and Light
Connections ....................................................... 33
AC Wiring Diagram ............................................ 34
DC Wiring Diagram—Mitsubishi .......................35
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DC Wiring Diagram—Kubota ............................36
DC Wiring Diagrams for Optional Equipment .37
Trailer Lights Wiring .......................................... 38
Section 7:Service Log
2 Owner’s Manual for MLT Light Tower
Section 1: Introduction and Safety
(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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Introduction and Safety
Introduction
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 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
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
that the unit is applied, used, and maintained in accordance
with the manufacturer's instructions and recommendations.
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 involve a hazard. The warnings in
this manual, and on tags and decals affixed to the unit are,
therefore, not all inclusive. If using a procedure, work
method or operating technique that the manufacturer does
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.
Throughout this publication, and on tags and decals affixed
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:
How to Obtain Service
When the unit requires servicing or repairs, contact a
Generac Mobile Products Authorized Dealer for assistance.
Service technicians are factory-trained and are capable of
handling all service needs.
Mobile Products Authorized Dealer about parts and
service, always supply the complete model number and
serial number of the unit as given on its data decal
located on the unit. Record the model number and serial
numbers in the spaces provided on the inside front cover
of this manual.
Owner’s Manual for MLT Light Tower 1
When contacting a Generac
NOTE: Notes contain additional information important to
a procedure and will be found within the regular text of
this manual.
These safety alerts cannot eliminate the hazards that they
indicate. Common sense and strict compliance with the
special instructions while performing the action or service
are essential to preventing accidents.
Introduction and Safety
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.
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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General Hazards
Explosion and Fire Hazards
Trailer Hazards
2 Owner’s Manual for MLT Light Tower
Electrical Hazards Battery Hazards
(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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Introduction and Safety
Owner’s Manual for MLT Light Tower 3
Always recycle batteries in accordance with local laws and
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
Introduction and Safety
(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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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
supplied with the unit when it was shipped from the factory.
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
• 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:
• Noticeable 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).
4 Owner’s Manual for MLT Light Tower
Introduction and 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
(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
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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Raising and Lowering the Mast
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.
service (oil/filter changes, cleaning, etc.) unless all
electrical components are shut down.
•
ALWAYS
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
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.
use extreme caution when servicing this
wash the unit with high pressure hoses,
DO NOT
• 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.
perform even routine
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 30 ft (9.14 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.
Owner’s Manual for MLT Light Tower 5
Introduction and Safety
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Towing Safety
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.
Hitch and Coupling
Verify the hitch and coupling on the towing vehicle
•
are rated equal to, or greater than, the trailer's
Gross Vehicle Weight Rating (GVWR).
• Verify the trailer hitch and the coupling are
compatible. Make sure the coupling is securely
fastened to the vehicle.
• DO NOT tow trailer using defective parts. Inspect
the hitch and coupling for wear or damage.
• 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.
• Attach the breakaway cable to the rear bumper of
the towing vehicle.
Reporting Trailer Safety Defects
If you believe your trailer has a defect which could cause
a crash or could cause injury or death, you should
immediately inform the National Highway Traffic Safety
Administration (NHTSA) in addition to notifying Generac
Mobile Products 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.gov; or write to:
Administrator
NHTSA
1200 New Jersey Avenue S.E.
Washington, DC 20590
You can also obtain other information about motor vehicle
safety from http://www.safercar.gov.
Running Lights
Verify directional and brake lights on the trailer are
connected and working properly
Wheels and Tires
•
Check trailer tires for wear and proper inflation.
• Verify wheel lug nuts are present and tightened to
the specified torque.
Safe Towing Techniques
•
Practice turning, stopping and backing up in an
area away from heavy traffic prior to transporting
the unit.
• Maximum recommended speed for highway towing
is 45 mph (72 km/h). Recommended off-road
towing speed is 10 mph (16 km/h) or less,
depending on terrain.
• When towing, maintain extra space between
vehicles and avoid soft shoulders, curbs and
sudden lane changes.
6 Owner’s Manual for MLT Light Tower
General Information
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Section 2: General Information
Specifications
DESCRIPTION UNITS MLT5060M MLT5060K
Engine
Make/Brand — MITSUBISHI KUBOTA
Model — L3E-W461ML D1005-E3BG1-MGM-1
EPA Tier — 4f 4f
Type — Diesel, liquid cooled, 4-stroke
Horsepower - prime hp (kW) 10.5 (7.8) 11.7 (8.7)
Horsepower - standby hp (kW) 12.2 (9.1) 13.1 (9.8)
Operating Speed rpm 1800 1800
Displacement
Cylinders qty 3 3
Fuel Consumption—100% Prime gph (Lph) 0.47 (1.78) 0.50 (1.89)
Battery Type—Group Number — 24 24
Battery Voltage quantity per unit 12V (1) 12V (1)
Battery Rating CCA-hour 440 440
Generator
Make/Brand — Marathon Electric Marathon Electric
Model — 201CSA5411 201CSA5411
Type, Insulation — Brushless, F Brushless, F
Output kW (kVA) 6.0 (6.0) 6.0 (6.0)
Output Voltage volts 120/240, single phase 120/240, single phase
Output Amperes 120V (240V) amperes 50 (25) 50 (25)
Frequency Hz Hertz 60 60
Power Factor — 1 (1Ø) 1 (1Ø)
Sound (23 ft at prime) dB (A) 70 70
Weights
Dry Weight lbs (kg) 2104 (954) 2104 (954)
Operating Weight lbs (kg) 2317 (1051) 2317 (1051)
Capacities
Fuel Tank Volume gal (L) 56 (212) 56 (212)
Usable Fuel Volume gal (L) 56 (212) 56 (212)
Coolant (including engine) qt (L) 4.5 (4.3) 4.8 (4.5)
Oil (including filter) qt (L) 3.8 (3.6) 5.4 (5.1)
Maximum Run Time hours 119 112
AC Distribution
Circuit Breaker Size amperes 30 30
Voltage Regulation — Capacitor +/-6% Capacitor +/-6%
Voltages Available 1Ø — 120, 240 120, 240
Lighting
Lighting Type — Metal Halide Metal Halide
Ballast Type — Coil & Core Coil & Core
Lumens — 440,000-462,000 440,000-462,000
Coverage
Trailer
Number of Axles 1 1
Capacity - Axle Rating lbs (kg) 3500 (1588) 3500 (1588)
Tire Size in 13 13
Hitch—Standard — 2” Ball 2” Ball
Maximum Tire Pressure psi 50 50
Specifications are subject to change without notice.
3
(L)
in
acres (m
2
)
57.97 (0.95) 61.08 (1.00)
5-7 (20,234 - 28,328) 5-7 (20,234 - 28,328)
Owner’s Manual for MLT Light Tower 7
General Information
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DESCRIPTION UNITS MLT5080M MLT5080K, MLT5080KCAN
Engine
Make/Brand — MITSUBISHI KUBOTA
Model — L3E-W461ML D1105-E3BG
EPA Tier — 4f 4f
Type — Diesel, liquid cooled, 4-stroke
Horsepower - prime hp (kW) 10.5 (7.8) 13.5 (10.1)
Horsepower - standby hp (kW) 12.2 (9.1) 15.4 (11.5)
Operating Speed rpm 1800 1800
Displacement
Cylinders qty 3 3
Fuel Consumption—100% Prime gph (Lph) 0.63 (2.38) 0.70 (2.65)
Battery Type—Group Number — 24 24
Battery Voltage quantity per unit 12V (1) 12V (1)
Battery Rating CCA-hour 440 440
Generator
Make/Brand — Marathon Electric Marathon Electric
Model — 201CSA5412 201CSA5412
Type, Insulation — Brushless, F Brushless, F
Output kW (kVA) 7.3 (7.3) 8.0 (8.0)
Output Voltage volts 120/240, single phase 120/240, single phase
Output Amperes 120V (240V) amperes 61 (30) 66 (33)
Frequency Hz Hertz 60 66
Power Factor — 1 (1Ø) 1 (1Ø)
Sound (23 ft at prime) dB (A) 70 70
Weights
Dry Weight lbs (kg) 2121 (963) 2121 (963)
Operating Weight lbs (kg) 2524 (1145) 2524 (1145)
Capacities
Fuel Tank Volume gal (L) 56 (212) 56 (212)
Usable Fuel Volume gal (L) 56 (212) 56 (212)
Coolant (including engine) qt (L) 4.5 (4.3) 4.8 (4.5)
Oil (including filter) qt (L) 3.8 (3.6) 5.4 (5.1)
Maximum Run Time hours 88 80
AC Distribution
Circuit Breaker Size amperes 40 40
Voltage Regulation — Capacitor +/-6% Capacitor +/-6%
Voltages Available 1Ø — 120, 240 120, 240
Lighting
Lighting Type — Metal Halide Metal Halide
Ballast Type — Coil & Core Coil & Core
Lumens — 440,000-462,000 440,000-462,000
Coverage
Tra iler
Number of Axles 1 1
Capacity - Axle Rating lbs (kg) 3500 (1588) 3500 (1588)
Tire Size in 13 13
Hitch—Standard — 2” Ball 2” Ball
Maximum Tire Pressure psi 50 50
Specifications are subject to change without notice.
3
(L)
in
acres (m
2
)
57.97 (0.95) 68.53 (1.12)
5-7 (20,234 - 28,328) 5-7 (20,234 - 28,328)
8 Owner’s Manual for MLT Light Tower
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