Generac Power Systems MLT4060M, MLT4060K, MLT4080M, MLT4080K Operating Manual
LIGHT TOWER
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MLT4060M • MLT4060K
MLT4080M • MLT4080K
OPERATING MANUAL
01447
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10454 O 09/15
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WARNING
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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.
ii
Introduction
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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. The information
contained in this manual was based on machines in production at the time of publication. Generac Mobile
Products reserves the right to change any portion of this information without notice.
Read all of the manuals included with the unit. Each manual details specific information regarding items such as
setup, use and service requirements. An engine operator’s manual provides detailed operation and maintenance
procedures for the engine.
DO NOT MODIFY or use this equipment for any application other than for which it was designed.
Generac Mobile Products recommends that a trained and licensed professional perform all electrical wiring and
testing functions. Any wiring should be in compliance with the National Electrical Code (NEC), and follow local, state
and Occupational Safety and Health Administration (OSHA) guidelines.
Engine Make:__________________________________________
Engine Serial Number:___________________________________
Engine Model Number: __________________________________
Generator Make: _______________________________________
Generator Model Number: ________________________________
Generator Serial Number: ________________________________
Unit Model Number:_____________________________________
Unit Serial Number: _____________________________________
iii
Table of Contents
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Introduction............................................................................................................................ iii
Section 1 - Safety
Safety Notes ....................................................................................................................................... 1
Operating Safety................................................................................................................................. 1
Engine Safety ..................................................................................................................................... 2
Service Safety .................................................................................................................................... 3
Towing Safety.....................................................................................................................................3
Reporting Trailer Safety Defects ........................................................................................................ 4
Safety Symbol Summary .................................................................................................................... 5
Section 2 - General Information
Specifications ..................................................................................................................................... 7
Unit Dimensions .................................................................................................................... 9
Unit Serial Number Locations...........................................................................................................10
Component Locations....................................................................................................................... 11
Control Panel - MLT4060M, MLT4060K........................................................................................... 12
Control Panel - MLT4080M, MLT4080K........................................................................................... 13
Section 3 - Operation
Light Tower Set Up...........................................................................................................................15
Prestart Checklist ............................................................................................................................. 16
Raising the Mast...............................................................................................................................17
Raising the Mast with Electric Winch Option .................................................................................... 18
Starting the Unit................................................................................................................................19
Light Operation ................................................................................................................................. 20
Derating for Altitude..........................................................................................................................20
Wet Stacking .................................................................................................................................... 20
Voltage Regulator Option ................................................................................................................. 21
Customer Convenience Receptacles ............................................................................................... 21
Shutting Down the Unit.....................................................................................................................21
Automatic Shutdown......................................................................................................................... 22
Lowering the Mast - Manual ............................................................................................................. 22
Lowering the Mast - Electric Winch Option.......................................................................................22
Electronically Lowering the Mast ......................................................................................... 22
Manually Lowering the Mast................................................................................................ 23
Removing the Lights for Transportation ........................................................................................... 24
Towing the Unit................................................................................................................................. 24
Lifting the Unit................................................................................................................................... 25
Section 4 - Maintenance
Daily Walk Around Inspection........................................................................................................... 27
General Maintenance ....................................................................................................................... 27
Basic Maintenance Schedule - Mitsubishi Engine............................................................................ 28
Basic Maintenance Schedule - Kubota Engine ................................................................................ 29
Winch Use, Operation & Maintenance - Manual .............................................................................. 29
Prior to Use.......................................................................................................................... 29
Operation............................................................................................................................. 30
Maintenance ........................................................................................................................ 30
Winch Preventive Maintenance Schedule ........................................................................... 31
Jack Maintenance............................................................................................................................. 31
Side-Wind Models ............................................................................................................... 31
Top-Wind Models ................................................................................................................ 32
Trailer Wheel Bearings ..................................................................................................................... 32
Section 5 - Troubleshooting
General Troubleshooting .................................................................................................................. 33
v
General Troubleshooting Guide ......................................................................................... 33
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Troubleshooting the Lights ............................................................................................................... 34
Troubleshooting the Lights Guide....................................................................................... 34
Section 6 - Wiring Diagrams
Mast Light Connections .................................................................................................................... 35
AC Wiring ......................................................................................................................................... 36
DC Wiring - Mitsubishi Engine..........................................................................................................37
DC Wiring - Kubota Engine .............................................................................................................. 38
DC Wiring Options............................................................................................................................39
DC Wiring Option - Electric Winch.................................................................................................... 40
Trailer Lights Wiring.......................................................................................................................... 41
Section 7 - Options & Accessories
Lower Radiator Hose Heater Option - Use and Maintenance .......................................................... 43
vi
SAFETY NOTES
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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.
The following formatting options will apply when calling the readers attention to the DANGERS, WARNINGS, CAUTIONS, NOTICES and NOTES.
INDICATES A HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN
Indicates a hazardous situation which, if not avoided, could result in death or serious
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
Section 1 - Safety
DANGER
DEATH OR SERIOUS INJURY.
WARNING
injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in property or equipment
damage.
Note: Notes contain additional information important to a procedure and will be found within the regular text body
of this manual.
OPERATING SAFETY
Before using the unit, be sure you read and understand all of the instructions. This equipment was
designed for specific applications; DO NOT modify or use this equipment for any application other than
which it was designed for. Equipment operated improperly or by untrained personnel can be dangerous.
Read the operating instructions and familiarize yourself with the location and proper use of all instruments
and controls. Inexperienced operators should receive instruction from someone familiar with the equipment
before being allowed to operate or set up the unit. The following points should be practiced at all times:
• The area immediately surrounding the unit should be dry, clean, and free of debris.
• Position and operate the unit on a firm, level surface.
• NEVER start a unit in need of repair.
• If the unit is equipped with a frame grounding stud, follow any local, state, and National Electrical
Code (NEC) guidelines when connecting.
• NEVER operate the unit on a combustible surface.
• NEVER operate a unit while tired, distracted, or under the influence of drugs or alcohol.
• Keep all body parts, clothing and other loose items away from moving parts.
• ALWAYS lower the mast when not in use, or if high winds or electrical storms are expected in the area.
• The mast extends up to 30 ft (9.14 m). ALWAYS make sure the area above the unit is open and clear
of overhead wires and obstructions.
• Keep area around the unit clear of people while raising and lowering the mast.
10454 O MLT4060-80M/K Operating Manual 1
Safety
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• 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.
• NEVER remove safety pin or pull mast locking pin while the mast is up.
• NEVER use the unit if insulation on electrical cord is cut or worn through.
• NEVER operate the lights without protective lens cover in place or with a lens cover that is cracked
or damaged.
• Only use mild soap and water to clean the lens covers. Other chemicals may have an adverse effect
on the glass.
• 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.
• Shut the engine down if any of the following conditions exist during operation:
1. Noticeable change in engine speed.
2. Loss of electrical output.
3. Equipment connected to the unit overheats.
4. Sparking occurs.
5. Engine misfires or there is excessive engine/generator vibration.
6. Protective covers are loose or missing.
7. If the ambient air temperature is above 120°F (49°C).
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 warnings
described in the engine operator's manual. A copy of this manual was supplied with the unit when it was
shipped from the factory.
• DO NOT run engine indoors or in an area with poor ventilation unless exhaust hoses are used. Engine
exhaust contains carbon monoxide, a deadly, odorless and colorless gas which, if inhaled, can cause
nausea, fainting or death. Make sure engine exhaust cannot seep into closed rooms or ventilation
equipment.
• DO NOT touch or lean against hot exhaust pipes or engine components.
• 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.
• Prolonged exposure to sound levels in excess of 85 dB(A) can cause permanent hearing loss. Wear
hearing protection when working around a running engine.
• Batteries contain sulfuric acid which can cause severe injury or death. Sulfuric acid can cause eye
damage, burn flesh or eat holes in clothing. Protective eye wear and clothing are necessary when
working on or around the battery. Always disconnect the negative (-) battery cable from the
corresponding terminal before performing any service on the engine or other components.
• NEVER open the radiator cap or oil drain plug while the engine is running or before the engine has
cooled down. Pressurized coolant and hot engine oil can cause severe burns. Allow the unit to cool
completely before attempting any service work.
2 MLT4060-80M/K Operating Manual 10454 O
• Keep area around exhaust pipes and air ducts free of debris to reduce the chance of an accidental fire.
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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.
• ALWAYS use extreme caution when servicing this 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.
• Replace all missing and hard to read decals. Decals provide important operating instructions and
warn of dangers and hazards.
• Before servicing the unit, make sure the Key switch and circuit breakers are in the OFF (O) position,
and the negative (-) terminal on the battery is disconnected. NEVER perform even routine service
(oil/filter changes, cleaning, etc.) unless all electrical components are shut down.
• NEVER start the unit under load. The circuit breakers must be in the OFF (O) position when starting
the unit.
• Wear heavy leather gloves when handling winch cables. Never let cables slip through bare hands.
Safety
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.
• Check that the hitch and coupling on the towing vehicle are rated equal to, or greater than, the trailer's
Gross Vehicle Weight Rating (GVWR).
• Check tires on trailer for tread wear, inflation, and condition.
• NEVER tow trailer using defective parts. Inspect the hitch and coupling for wear or damage.
• Make sure the trailer hitch and the coupling are compatible. Make sure the coupling is securely fastened
to the vehicle.
• Make sure directional and brake lights on the trailer are connected and working properly.
• Check that the lug nuts holding the wheels are tight and that none are missing.
• 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 terrain.
• When towing, maintain extra space between vehicles and avoid soft shoulders, curbs and sudden
lane changes. If you have not pulled a trailer before, practice turning, stopping and backing up in an
area away from heavy traffic.
• A film of grease on the coupler will extend coupler life and eliminate squeaking. Wipe the coupler
clean and apply fresh grease each time the trailer is towed.
• Connect safety chains in a crossing pattern under the tongue.
• Before towing the trailer, check 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.
10454 O MLT4060-80M/K Operating Manual 3
Safety
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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.
4 MLT4060-80M/K Operating Manual 10454 O
Safety
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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.
UV
Safety alert symbol; used to
alert you to potential personal
injury hazards.
Hot surface(s) nearby.
Belt/entanglement hazard; keep
body parts clear of this area.
Fan hazard; keep body parts
clear of this area.
Crush hazard; keep body parts
clear of this area.
Ultraviolet radiation hazard;
operate only with lens intact.
Asphyxiation hazard; operate
in well ventilated area.
Dangerous voltage may be
present.
Anchor/tie down point.
Forklift here only.
Use clean diesel fuel only.
Burn/scald hazard;
pressurized steam.
Stop engine before fueling.
Fire/explosion hazard; keep
open flames away from unit.
Lift here only.
Figure 1 - Safety Symbol Summary
Read and understand the
supplied operator’s manual
before operating unit.
Unit electrical ground.
00197
10454 O MLT4060-80M/K Operating Manual 5
Section 2 - General Information
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SPECIFICATIONS
GENERAC MODEL MLT4060M MLT4060K
Engine
Make/Brand............................................................................. Mitsubishi ................................Kubota
Model ......................................................................................L3E-W461ML ..........................D1005-E3BG1-MGM-1
EPA Tier ..................................................................................F4 ............................................F4
Type ........................................................................................ Diesel, liq. cooled, 4-stroke .....Diesel, liq. 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 in
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 .........................................................................440 CCA.................................. 440 CCA
Generator
Make/Brand............................................................................. Marathon Electric ....................Marathon Electric
Model ......................................................................................201CSA5411...........................201CSA5411
Type, Insulation....................................................................... Brushless, F ............................Brushless, F
Generator Set (Engine/Generator)
Output kW (kVA).....................................................................6.0 (6.0) ...................................6.0 (6.0)
Output Voltage V.....................................................................120/240, single phase .............120/240, single phase
Output Amperes 120V (240V) A .............................................50 (25) ..................................... 50 (25)
Frequency Hz.......................................................................... 60 ............................................60
Power Factor........................................................................... 1 (1Ø) ......................................1 (1Ø)
3
(L) ..............................................................57.97 (0.95) .............................61.08 (1.00)
Weights
Dry Weight lbs (kg).................................................................1675 (760) ............................... 1695 (770)
Operating Weight lbs (kg) ......................................................1888 (856) ..............................1908 (866)
Capacities
Fuel Tank Volume gal (L)........................................................30 (114) ...................................30 (114)
Usable Fuel Volume gal (L)....................................................30 (114) ...................................30 (114)
Coolant (incl. engine) qt (L) ....................................................4.5 (4.3)...................................4.8 (4.5)
Oil (incl. filter) qt (L) ................................................................3.8 (3.6)...................................5.4 (5.1)
Maximum Run Time hrs .........................................................64 ............................................60
Lighting
Lighting Type...........................................................................Metal Halide ............................Metal Halide
Ballast Type.............................................................................Coil & Core.............................. Coil & Core
Lumens ...................................................................................440,000 ...................................440,000
Coverage acres (m²) ...............................................................5 - 7 (20,234 - 28,328) ............5 - 7 (20,234 - 28,328)
AC Distribution
Circuit Breaker Size ................................................................30 ............................................30
Voltage Regulation..................................................................Capacitor +/- 6% .....................Capacitor +/- 6%
Voltages Available 1Ø .............................................................120, 240 ..................................120, 240
Trailer
Number of Axles......................................................................1 ..............................................1
Capacity - Axle Rating lbs (kg)............................................... 2200 (998)...............................2200 (998)
Tire Size in.............................................................................. 13 ............................................13
Hitch - Standard ......................................................................2'' ball ...................................... 2'' ball
Maximum Tire Pressure psi....................................................50 ........................................... 50
Specifications are subject to change without notice.
10454 O MLT4060-80M/K Operating Manual 7
General Information
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GENERAC MODEL MLT4080M MLT4080K
Engine
Make/Brand............................................................................. Mitsubishi ................................Kubota
Model ......................................................................................L3E-W461ML ..........................D1005-E3BG
EPA Tier ..................................................................................F4 ............................................F4
Type ........................................................................................ Diesel, liq. cooled, 4-stroke .....Diesel, liq. 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 in
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 .........................................................................440 CCA.................................. 440 CCA
Generator
Make/Brand............................................................................. Marathon Electric ....................Marathon Electric
Model ......................................................................................201CSA5412...........................201CSA5412
Type, Insulation....................................................................... Brushless, F ............................Brushless, F
Generator Set (Engine/Generator)
Output kW (kVA).....................................................................7.3 (7.3) ...................................8.0 (8.0)
Output Voltage V.....................................................................120/240, single phase .............120/240, single phase
Output Amperes 120V (240V) A .............................................61 (30) ..................................... 66 (33)
Frequency Hz.......................................................................... 60 ............................................60
Power Factor........................................................................... 1 (1Ø) ......................................1 (1Ø)
3
(L) ..............................................................57.97 (0.95) .............................68.53 (1.12)
Weights
Dry Weight lbs (kg).................................................................1695 (769) ............................... 1712 (777)
Operating Weight lbs (kg) ......................................................1908 (865) ..............................1925 (874)
Capacities
Fuel Tank Volume gal (L)........................................................30 (114) ...................................30 (114)
Usable Fuel Volume gal (L)....................................................30 (114) ...................................30 (114)
Coolant (incl. engine) qt (L) ....................................................4.5 (4.3)...................................4.8 (4.5)
Oil (incl. filter) qt (L) ................................................................3.8 (3.6)...................................5.4 (5.1)
Maximum Run Time hrs .........................................................48 ............................................43
Lighting
Lighting Type...........................................................................Metal Halide ............................Metal Halide
Ballast Type.............................................................................Coil & Core.............................. Coil & Core
Lumens ...................................................................................440,000 ...................................440,000
Coverage acres (m²) ...............................................................5 - 7 (20,234 - 28,328) ............5 - 7 (20,234 - 28,328)
AC Distribution
Circuit Breaker Size ................................................................40 ............................................40
Voltage Regulation..................................................................Capacitor +/- 6% .....................Capacitor +/- 6%
Voltages Available 1Ø .............................................................120, 240 ..................................120, 240
Trailer
Number of Axles......................................................................1 ..............................................1
Capacity - Axle Rating lbs (kg)............................................... 2200 (998)...............................2200 (998)
Tire Size in.............................................................................. 13 ............................................13
Hitch - Standard ......................................................................2'' ball ...................................... 2'' ball
Maximum Tire Pressure psi....................................................50 ........................................... 50
Specifications are subject to change without notice.
8 MLT4060-80M/K Operating Manual 10454 O
Unit Dimensions
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General Information
B
A
C
D
E
00208
Figure 1 - Unit Dimensions
ABCDE
MLT4060M/K,
MLT4080M/K
Specifications are subject to change without notice.
10454 O MLT4060-80M/K Operating Manual 9
170 in
(4.32 m)
70 in
(1.78 m)
30 ft
(9.14 m)
63 in
(1.73 m)
140 in
(3.56 m)
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