Generac Power Systems MLT4060M, MLT4060K, MLT4080M, MLT4080K Operating Manual

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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.

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

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

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.

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)

(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)

(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

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)

General Information

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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.

Unit ID Tag

Located on inside

of front panel

Manufactured by Generac Mobile Products LLC

VIN Tag

MANUFACTURED BY/FABRIQUE PAR: Generac Mobile Products LLC DATE: 00/0000 GVWR/PNBV: 000KG (0000LBS) COLD INF. PRESS./ PRESS. DE

GAWR / PNBE TIRE / PNEU RIM / JANTE GONF A FROID - KPA(PSI/LPC) SGL / DUAL

EACH AXLE

THIS VEHICLE CONFORMS TO ALL APPLICABLE STANDARDS PRESCRIBED UNDER THE U.S. FEDERAL MOTOR VEHICLE SAFETY STANDARDS(FMVSS) AND CANADIAN MOTOR VEHICLE SAFETY REGULATIONS IN EFFECT ON THE DATE OF MANUFACTURE.

CE VEHICULE EST CONFORME A TOUTES LES NORMES QUI LUI SONT APPLICABLES EN VERTU DU REGLEMENT SUR LA SECURITE DES VEHICULES AUTOMOBILES DU CANADA EN VIGUEUR A LA DATE SA FABRICATION.

00000000000000000

V.I.N./N.I.V.:

XXX000

MODEL:

TYPE:

TRAILER

TIRE AND LOADING INFORMATION

RENSEIGNEMENTS SUR LES PNEUS ET LE CHARGEMENT

The weight of cargo should never exceed 0000KG (0000LBS) Le poids du chargement ne doit jamais depasser 0000KG (0000LBS)

SEE OWNER’S MANUAL FOR

ADDITIONAL

INFORMATION

VOIR LE

MANUEL DE

L’USAGER

POUR

PLUS DE

RENSEIGNEMENTS

(920) 361-4442 (800) 926-9768

Country of Origin

Manufacturing Code

1 ph. 1.0PF 3 ph. .8PF 3 ph. 1.0PF

KVA

Serial Number

Model

Weight (lbs/kg) RPM/Frequency

Rating

FOR ELECTRICAL EQUIPMENT

Y. POUR MATERIAL

ONL

ELECTRIQUE SEULEMENT.

209649

Form: SFC626B

Ins. Class

Figure 2 - Serial Number Locations

01451

10 MLT4060-80M/K Operating Manual 10454 O

COMPONENT LOCATIONS

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General Information

LEFT SIDE

RIGHT SIDE

01983

Figure 3 - Component Locations

1. Mast rotation knob 6. Control box

2. Central lift point 7. Radiator access

3. Engine exhaust 8. Fuel fill

4. Forklift pockets 9. Outriggers

5. Battery 10. Engine access

10454 O MLT4060-80M/K Operating Manual 11

General Information

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CONTROL PANEL - MLT4060M, MLT4060K

TURN MAIN

BREAKER

OFF

120V

BREAKER

MAIN

BREAKER

240V

ON ON ON ON

BALLAST INDICATOR LIGHTS

MAST LIGHT SWITCHES

GLOW

PLUG

OFF

RUN

START

GLOW PLUG

INDICATOR

120V

240V

BREAKER

NEUTRAL BONDED TO FRAME

Figure 4 - Control Panel Component Locations (MLT4060M, MLT4060K)

1. Main circuit breaker 7. DC breaker

2. Light switches (4) 8. 120V GFCI receptacle

3. Ballast indicator lights (4) 9. 240V twist-lock receptacle

4. Control Power switch 10. 120V breaker

5. Glow plug indicator 11. Circuit breaker indicator light

Engine hour meter

00165

12 MLT4060-80M/K Operating Manual 10454 O

CONTROL PANEL - MLT4080M, MLT4080K

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General Information

MAIN

BREAKER

240V

120V

BREAKER

120V

TURN MAIN

BREAKER

OFF

120V

BREAKER

120V

ON ON ON ON

240V

BREAKER

240V

BALLAST INDICATOR LIGHTS

MAST LIGHT SWITCHES

GLOW

PLUG

OFF

RUN

START

GLOW PLUG

INDICATOR

BREAKER

NEUTRAL BONDED TO FRAME

Figure 5 - Control Panel Component Locations (MLT4080M, MLT4080K)

1. Main circuit breaker 7. Engine hour meter

2. Light switches (4) 8. DC breaker

3. Ballast indicator lights (4) 9. 120V GFCI receptacles (2)

4. 240V breaker 10. 240V twist-lock receptacle

5. Control Power switch 11. 120V breaker

6. Glow plug indicator 12. Circuit breaker indicator light

00162

10454 O MLT4060-80M/K Operating Manual 13

Section 3 - Operation

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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 30 ft (9.14 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 C

DETAIL D

DETAIL G

Figure 6 - Light Tower Set Up

2. Place the unit on firm ground that is relatively flat, then block the wheels to keep it from moving (A). This will make it easier to level the unit.

3. Pull the locking pin on the tongue jack and rotate the jack 90°. Replace the locking pin (B). Turn the jack handle clockwise to raise the trailer tongue off of the towing vehicle.

DETAIL H

00151

4. A grounding stud is located on the frame of the trailer at the base of the mast post (C). For grounding requirements, follow any local, state, or National Electrical Code (NEC) guidelines.

5. Pull the locking pin (D) on the outrigger (E) and pull each outrigger out until the spring loaded locking pin snaps back into place. Pull the locking pin on the outrigger jack and rotate each jack 90° so the jack pad is facing down. Replace the locking pin.

10454 O MLT4060-80M/K Operating Manual 15

Operation

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6. Pull the locking pin on the rear jack (F) and rotate the jack 90°. Replace the locking pin. Turn the jack handle clockwise to start leveling the trailer. Adjust all four jacks by turning their handles clockwise (G) until they are firmly in contact with the ground and the trailer is as level as possible.

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. Tighten the hardware completely and make sure the lamps are connected to the junction box (J).

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.  Verify 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.  The unit must be dry. Check for any water inside, on, or near the unit; dry if needed.  For grounding requirements, follow any local, state, or National Electrical Code (NEC) guidelines.  Verify the Control Power switch is in the OFF (O) position.  Verify all circuit breakers are in the OFF (O) position.  Inspect all electrical cords; repair or replace any that are cut, worn, or bare.  Verify all winch cables are in good condition and centered on each pulley. Do not use if cables are

kinked or beginning to unravel.

 Check oil, coolant, and fuel levels. For more information, refer to “General Maintenance” on page 27.  Verify battery connections are secure.  Turn the battery disconnect switch on, if equipped.  Verify the engine fan belt tension and condition.  Verify the engine fan belt guard.  Verify the engine exhaust system for loose or rusted components.  Verify all covers are in place and secure.

16 MLT4060-80M/K Operating Manual 10454 O

RAISING THE MAST

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1. Set up and level the unit. Refer to “Light Tower

Set Up” on page 15.

WARNING

The unit must be leveled with

the outriggers extended before

raising the mast. The

outriggers must remain

extended while the mast is up.

Failure to level the unit or extend the outriggers will

severely reduce the stability

and could allow the unit to tip

and fall.

2. Remove mast cradle locking pin from mast cradle (A).

DETAIL A DETAIL C

Operation

DETAIL E

STOP

DETAIL G

3. Check the mast cables for excessive wear or damage. Make sure the cables are properly centered in each pulley (B). Check the electrical cord for damage.

WARNING

Do not start the unit if

insulation on the electrical

cord is cut or worn through.

Bare wires in contact with the

mast or frame may energize the

unit and cause electrocution.

Repair or replace a damaged

cord.

4. Make sure the area around the unit is clear before raising the mast to the vertical position.

5. Remove the safety pin from the mast lock bar (C). Using the handle for the lower mast winch (D), raise the mast until it is vertical and the tab on the mast is positioned into the mast lock. The mast lock bar should snap into place automatically. Secure the lock with the safety pin (E).

B C,E

00178

Figure 7 - Raising the Mast - Manual Winch

6. After the mast is up and locked into place, use the upper mast winch (F) to telescope the mast to the desired height. Extend the mast slowly, making sure the electrical cord is extending at the top sections of the mast. If, for any reason, the winch cable begins to develop slack or any of the mast sections get stuck, STOP IMMEDIATELY and contact an authorized service center.

CAUTION

Do not extend the mast beyond the colored mark on the middle mast tube (G).

7. Rotate the mast by loosening the mast rotation knob at the bottom of the mast (H). Turn the mast until the lights face in the desired direction and then tighten the mast rotation knob to secure the mast in position.

10454 O MLT4060-80M/K Operating Manual 17

Operation

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WARNING

Never raise or lower the mast while the unit is operating. Never remove the safety pin or release the mast lock while the mast is up. Releasing the lock will cause the mast

to fall.

RAISING THE MAST WITH ELECTRIC WINCH OPTION

1. Set up and level the unit. Refer to “Light Tower

Set Up” on page 15.

WARNING

The unit must be leveled with

the outriggers extended before

raising the mast. The

outriggers must remain

extended while the mast is up.

Failure to level the unit or extend the outriggers will

severely reduce the stability

and could allow the unit to tip

and fall.

DETAIL C

DETAIL E

STOP

DETAIL D

DETAIL F

2. Remove mast cradle locking pin from mast cradle (A).

3. Check the mast cables for excessive wear or damage. Make sure the cables are properly centered in each pulley (B). Check the electrical cord for damage.

DETAIL G

DETAIL H

WARNING

Do not start the unit if

insulation on the electrical

cord is cut or worn through.

Bare wires in contact with the

mast or frame may energize the

unit and cause electrocution.

Repair or replace a damaged

cord.

4. Make sure the area around the unit is clear before raising the mast to the vertical position.

5. Remove the safety pin from the mast lock bar (C). Press the lower winch control switch (D) upward to raise the mast into the vertical position. Hold the switch until the mast lock is engaged. The mast lock bar should snap into place automatically. Secure the lock with the safety pin (E).

C,E H

Figure 8 - Raising the Mast - Electric Winch

00188

Note: A limit switch on the mast tube will disconnect power to the lower electric winch to prevent deadheading the winch.

6. Press and hold the upper winch control switch (F) upward to telescope the mast to the desired height. Extend the mast, making sure that the coiled electrical cord is extending at the top sections of the mast. If, for any reason, the winch cable begins to develop slack or any of the mast sections get stuck, STOP IMME- DIATELY and contact an authorized service center.

18 MLT4060-80M/K Operating Manual 10454 O

Operation

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CAUTION

Do not extend the mast beyond the colored mark on the middle mast tube (G). A limit switch

on the main mast section will disconnect power to the upper electric winch to prevent

overextending the mast.

WARNING

Never raise or lower the mast while the unit is operating. Never remove the safety pin or release the mast lock while the mast is up. Releasing the lock will cause the mast

to fall.

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.

1. Check that the main circuit breaker and individual circuit breakers for each of the lights are in the OFF (O) position.

Note: When the red Turn Main Breaker Off light is illuminated, the main circuit breaker must be turned OFF

CIRCUIT BREAKERS

(O).

2. Turn the key on the Control Power switch to the left Glow Plug position and hold the key in place

for five seconds, or until the glow plug indicator turns red. (Kubota units do not have a glow plug

indicator.) As soon as it is glowing, turn the key to the right Start position and hold it until the engine cranks and starts running. Release the key, it will move to the Run position.

Figure 9 - Circuit Breakers

Note: For cold weather conditions, refer to the engine operator’s manual for appropriate glow plug interval.

CTIVATE GLOW PLUG

OFF

GLOW

PLUG

RUN

START

CRANK ENGINE TO START

GLOW

PLUG

OFF

RUN

START

RELEASE KEY

OFF

GLOW

PLUG

RUN

START

00203

00202

Figure 10 - Control Power Switch Positions

Do not crank the engine longer than 10 seconds at a time. If the engine will not start, wait

30 seconds to allow the starter motor to cool and then repeat the starting procedure.

Excessive cranking will cause damage to the starter.

Note: If oil pressure is not obtained within 15 seconds after the key is switched to the Run position, the low oil automatic shutdown will turn off the fuel supply, stopping the engine. Check the oil level and turn the key to the OFF position to reset the oil pressure timer before attempting to restart the engine.

10454 O MLT4060-80M/K Operating Manual 19

Operation

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3. Once the engine is running, allow it to reach normal operating temperature before switching on any loads.

LIGHT OPERATION

WARNING

NEVER operate the lights without the protective lens cover, or with a lens cover that is cracked or damaged. The bulbs in the light fixtures produce high temperatures and

operate under pressure. A broken or missing lens cover could cause the bulbs to

shatter, causing injury.

1. Once the engine is up to temperature and running

BALLAST INDICATOR LIGHTS

MAST LIGHT SWITCHES

GLOW PLUG

OFF

RUN

START

GLOW PLUG INDICATOR

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.

3. The ballast indicator lights (C) will come on and continue to get brighter as the lights warm up, and then remain on. This confirms that power is coming from the ballasts to the lights.

TURN

MAIN

BREAKER

OFF

BREAKER

MAIN

BREAKER

240V

120V

IOIOIOI

ON ON ON ON

4. If an indicator light does not come on, the ballast

240V

BREAKER

may need to be serviced. If the indicator light comes on and stays lit, but the related light is not illuminated, check the bulb or the mast wiring. Refer to “Troubleshooting the Lights” on

NEUTRAL BONDED TO FRAME

00147

page 34.

Figure 11 - Light Operation

5. The lights require a warm up period of 5-15 minutes before they reach full output. If the lights are shut down, they require a cool down period of approximately 10 minutes before they can be switched on again.

6. The light tower uses four 1000W bulbs. When checking or replacing the bulbs, wipe them with a clean cloth to avoid leaving any grease, oil residue or fingerprints on the glass. Any residue can create a hot spot on the bulb, causing premature bulb failure.

CAUTION

Bulbs become extremely hot when in use. Allow bulb fixture to cool 10-15 minutes before

handling or lowering the mast.

DERATING FOR ALTITUDE

All units are subject to derating for altitude and temperature; this will reduce the available power for operating tools

and accessories connected to the receptacles. Typical reductions in performance are 2-4% for every 1000 ft (305 m) of elevation and 1% per 10ºF (5.6ºC) increase in ambient air temperature over 72ºF (22ºC).

WET STACKING

The unit is powered by a diesel engine. Diesel engines are susceptible to wet stacking if lightly loaded. Wet stacking occurs when an engine is run at less than 30% of its full load capacity, causing unburned fuel to accumulate in the exhaust system. Wet stacking can be detected by continuous black exhaust when the unit is under a constant load. It can also cause fouling of injectors and buildup on engine valves. Diesel engines operate properly when applied loads are between 30% and 100% capacity. Appropriate generator sizing is determined by the anticipated load. If the unit is in a wet stack condition, load the unit heavily for five hours or until the exhaust is clear.

20 MLT4060-80M/K Operating Manual 10454 O

Operation

120V 120V

240V

BREAKER BREAKER

240V

BREAKER

NEUTRAL BONDED TO FRAME

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VOLTAGE REGULATOR OPTION

The electronic voltage regulator controls the output of the generator by regulating the current into the exciter field. The regulator has three screwdriver adjustable potentiometers that may be adjusted for voltage, stability and voltage roll-off (U/F). The voltage regulator on your unit is adjusted before shipment from the factory. Contact Generac Mobile Products for additional information before attempting to adjust the voltage regulator.

CUSTOMER CONVENIENCE 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.

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. Should the breaker trip, switch off the lights, remove some of the load to the receptacles and wait 10 minutes for the bulbs to cool before turning them back on.

120V GFCI

Receptacles

Figure 12 - Receptacle Locations

240V

Twist-lock

Receptacle

00114

With all of the lights off, the full generator output may be used with the optional 240V twist-lock receptacle.

SHUTTING DOWN THE UNIT

Prior to shutting down the unit, check with personnel using power supplied by the unit and let them know the power is going to be turned off. Make sure the power shut down will not create any hazards by accidentally turning off equipment that needs to be kept on (pumps, compressors, lights, etc.).

When you have finished using the unit, proceed with shut down as follows:

1. Remove any loads from the receptacles.

2. Switch the individual circuit breakers for each light and each receptacle to the OFF (O) position.

3. Switch the main circuit breaker to the OFF (O) position.

4. Turn the Control Power switch to the OFF (O) position.

CIRCUIT BREAKERS

OIO

CONTROL POWER SWITCH

OFF

GLOW

PLUG

RUN

START

00201

Figure 13 - Circuit Breakers and Control Power Switch Positions

Note: For extended storage time, disconnect the battery. For extended storage requirements, refer to the engine operator’s manual.

10454 O MLT4060-80M/K Operating Manual 21

Operation

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AUTOMATIC SHUTDOWN

This unit is equipped with a low oil pressure and high coolant temperature automatic shutdown system. This system will automatically shut off the fuel supply to stop the engine if oil pressure drops too low or the engine exceeds normal operating temperature. Return the Control Power switch to the OFF position to reset the unit after you have determined the cause of the shutdown.

LOWERING THE MAST - MANUAL

1. Shut down the lights and engine, refer to “Shutting Down the Unit” on page 21. 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.

Note: For transportation, Generac Mobile Products strongly recommends the lights be removed from the mast and stowed. Refer to “Removing the Lights for Transportation” on page 24.

3. Turn the upper mast winch handle counterclockwise to collapse the mast to its lowest position. Ensure the electrical cord does not get caught in, or pinched by, the mast while it is being lowered.

CAUTION

STOP IMMEDIATELY if the mast hangs up or the winch cable begins to develop slack.

Excess slack in the cable could cause the mast to collapse, which could result in personal

injury or equipment damage. Contact an authorized service center.

4. Release the mast lock by pulling the safety pin on the mast lock and pulling the lock bar free. Turn the handle of the lower mast winch counterclockwise until the mast rests in the transport cradle.

Note: If the mast lock bar does not pull free, activate the lower winch slightly to relieve pressure on the mast bar.

5. After the mast is completely down, insert the mast cradle locking pin and secure it with the safety pin.

LOWERING THE MAST - ELECTRIC WINCH OPTION

Electronically Lowering the Mast

1. Shut down the lights and engine, refer to “Shutting Down the Unit” on page 21. 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.

Note: For transportation, Magnum Power Products LLC strongly recommends the lights be removed from the mast and stowed. Refer to “Removing the Lights for Transportation” on page 24.

22 MLT4060-80M/K Operating Manual 10454 O

Operation

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3. Press and hold the upper winch control switch downward to collapse the mast to its lowest position. Ensure the electrical cord does not get caught in, or pinched by, the mast while it is being lowered.

Note: Some electric winch models are equipped with an anti-backlash safety limit switch. This switch will disconnect power to the winch if excess cable slack is detected, preventing accidental lowering of the mast.

CAUTION

STOP IMMEDIATELY if the mast hangs up or the winch cable begins to develop slack.

Excess slack in the cable could cause the mast to collapse, which could result in personal

injury or equipment damage. Contact an authorized service center.

4. Release the mast lock by pulling the safety pin on the mast lock and pulling the lock bar free. Lower the mast by holding the lower winch control switch to the right until the mast is resting in the transport cradle.

Note: If the mast lock bar does not pull free, activate the lower winch slightly to relieve pressure on the mast bar.

5. After the mast is completely down, insert the mast cradle locking pin and secure it with the safety pin.

Note: If the generator is not operational, and the batteries do not have enough power to lower the mast, it may be necessary to lower the mast manually.

Manually Lowering the Mast

Do not use this procedure unless it is absolutely necessary. Continuous use of this procedure

could damage the planetary gear brake of the winch. This procedure will not work if the

planetary gear brake is damaged.

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. When the mast is completely down, reinstall the winch motor assembly, securing it with the screws retained in step 2.

Figure 14 - Winch Motor Disassembly

00161

10454 O MLT4060-80M/K Operating Manual 23

Operation

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REMOVING THE LIGHTS FOR TRANSPORTATION

1. On units equipped with quick disconnect fittings for the lights, disconnect the power cords from the junction box at the top of the mast. Replace the dust caps on the junction box. On hard wired units, remove the junction box cover, located on the top of the mast, and disconnect ONLY the mast light wires from the connectors. To release the mast light wires from the connectors, flip the locking levers down and pull out the appropriate wires.

2. Remove the lights from the mast by removing the wing nut that holds the light fixture bracket to the cross tube. Attach the lights to the storage brackets (if equipped) located on the mast tube on either side of the central lift point.

00232

Figure 15 - Disconnect

Wires from Connectors

TOWING THE UNIT

Once the engine is shut down and the mast and lights are properly stowed, follow these steps to prepare the unit for towing.

1. Raise the rear jack completely and release the locking pin to rotate it up into the travel position. Make sure the locking pin snaps into place.

2. Raise the outrigger jacks completely and release the locking pins to rotate them up into the travel position. Make sure the locking pins snap into place. Release the outrigger locking pins and slide the outriggers into the trailer frame until the locking pins snap into place.

3. Use the tongue jack to raise or lower the trailer onto the hitch of the towing vehicle. Lock the hitch coupling and attach the safety chains or cables to the vehicle. Remove the tongue jack locking pin and rotate the jack into the travel position. Replace the locking pin.

Note: 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 unit is towed.

4. To ensure proper operation of the jacks, lube the grease fittings located on the leveling jacks. Refer to “Jack

Maintenance” on page 31. For maintenance interval information, refer to Basic Maintenance Schedules

beginning on page 28.

5. Connect any trailer wiring to the tow vehicle. Check for proper operation of the directional and brake lights.

6. Make sure the mast cradle locking pin is in place.

7. Make sure the doors are properly latched.

8. If the unit is going to be driven over rough ground, remove the bulbs from the light fixtures.

9. Check for proper inflation of the trailer tires. For maximum tire pressures, refer to Specifications beginning on page 7.

24 MLT4060-80M/K Operating Manual 10454 O

10. Check the wheel lugs. Tighten or replace any lugs that are loose or missing. If

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a tire has been removed for axle service or replaced, tighten the lugs, in the order shown, to the following specifications:

Operation

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).

Note: After the first road use, re-torque the lug nuts in sequence.

Figure 16 - Lug Sequence

4. 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.

00204

LIFTING THE UNIT

A central lift point is located on the top of the unit. The

central lift point is connected to a lift structure inside the unit. Attach a sling or hook directly to the central lift point only if the devices are in good condition and the equipment being used to raise the unit has sufficient capacity. For approximate weights, refer to Specifications beginning on page 7. Make sure the cradle locking pin is in place. Always remain aware of people and objects around when moving or lifting the unit. Keep the doors closed and locked. Use the upper or lower forklift pockets with care. Approach the unit as perpendicular as possible to avoid any damage to the unit. Make sure any obstructions

are clear of the forklift tines before lifting.

Central

Lift Point

Upper Forklift Pockets

Lower Forklift Pockets

00136

Figure 17 - Unit Lift Points

Note: When using the central lift point, the mast must be in the stowed position.

10454 O MLT4060-80M/K Operating Manual 25

Section 4 - Maintenance

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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.

DAILY WALK AROUND INSPECTION

Look for conditions that could hinder performance or safety, such as (but not limited to) oil/coolant/fuel leakage, blocked vents, loose/missing hardware, and electrical connections.

Visually inspect the fan belt for cracks, fraying, stretching, and verify the belt is properly seated in the pulley grooves. Replace the belt according to the manufacturer’s recommendations.

Note: At the 500 hour/12 month service interval, it is recommended that the belt be removed and checked for wear. While the belt is removed, inspect pulleys and bearings. Rotate and feel for hard turning or unusual sounds. If pulleys or bearings need replacement, contact the engine manufacturer.

Failure to perform a daily inspection may result in serious damage to the prime mover.

GENERAL MAINTENANCE

Poorly maintained equipment can become a safety hazard. In order for the equipment to operate safely and properly over a long period of time, periodic maintenance and occasional repairs are necessary. NEVER perform routine service (oil/filter changes, cleaning, etc.) unless all electrical components are shut off. Before servicing the unit, always follow the instructions listed below.

• Verify the Control Power switch is turned to the OFF (O) position.

• Verify the circuit breakers are turned to the OFF (O) position.

• Disconnect the negative (-) terminal on the battery.

• Attach a “Do Not Start” sign to the control panel. This will notify everyone that the unit is being serviced and

will reduce the chance of someone inadvertently trying to start the unit.

• Never wash the unit with a high pressure hose or with any kind of power washer.

• Never wash the engine block or fuel tank with a power washer or steam cleaner. Water may enter the cabinet

and collect in the generator windings or other electrical parts, causing damage.

• If the unit is stored outside, check for water inside the cabinet and generator before each use. If wet, dry the

unit thoroughly before starting.

• Inspect condition of electrical cords. DO NOT use the unit if insulation is cut or worn through.

• Check that winch cables are in good condition and are centered on each pulley. DO NOT use a cable that

is kinked or starting to unravel.

• Check that the safety pins for the mast lock rod and mast lock bar are present and secured with a chain.

Check that the spring located in the mast lock bar is not broken or missing. Check the operation of the mast lock bar.

• Check the wheel lugs. Refer to “Towing the Unit” on page 24.

• Check the coolant level daily. Refer to the engine operator’s manual for coolant recommendations and proper

mixture.

○ Coolant is checked visually by inspecting the level in coolant overflow jug located near the radiator. ○ Normal operating level is between the full and add markings on the overflow jug known as normal range. ○ WHEN ENGINE IS STOPPED AND COMPLETELY COOL, coolant may be added directly to the coolant

10454 O MLT4060-80M/K Operating Manual 27

Maintenance

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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. ○ Add oil only if the oil level is below the add mark on the bottom of the cross-hatch pattern on the dipstick.

DO NOT OVERFILL the crankcase.

• Check the fuel level.

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.

BASIC MAINTENANCE SCHEDULE - MITSUBISHI 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. For additional or replacement copies of the engine operator’s manual, contact an authorized dealer in your area.

Item Daily

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  Fuel Tank - Drain Water  Check Air Cleaner  Replace Engine Oil And Oil Filter * Belt And Belt Tension - Inspect And Adjust  Replace Fuel Filter  Drain And Clean Fuel Tank ** Check Glow Plugs  Lubricate Leveling Jacks  Bolts And Nuts On The Engine - Retighten * Replace Heated Fuel Filter (If Equipped)  Inspect Engine Starting Battery  Air Cleaner Element - Clean, Check And Replace  Fuel System - Bleed Air  Water Sedimenter - Drain Water 



Hours

250

Hours

400

Hours

500

Hours

1000

Hours

Required

* Perform after the initial 50 hours of operation, then on the regularly scheduled interval indicated in the schedule

above.

** Certain conditions may require the fuel tank to be drained and cleaned more often. When operating in extremely

28 MLT4060-80M/K Operating Manual 10454 O

Maintenance

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dusty conditions, clean the fuel tank as often as necessary.

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.

Item Daily

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  Change Engine Oil * Check Intake Air Line  Replace Oil Filter Cartridge * Replace Fuel Filter Cartridge  Clean Water Separator  Lubricate Leveling Jacks  Remove Sediment In Fuel Tank  Replace Fan Belt  Replace Air Filter Element **

Hours

100

Hours

200

Hours

400

Hours

500

Hours1 Year

* Change the engine oil and oil filter after the initial 50 hours of operation, then at the appropriate interval thereafter. ** Replace the air cleaner element yearly, or after six cleanings, whichever occurs first.

WINCH USE, OPERATION & MAINTENANCE - MANUAL

Prior to Use

• Inspect rope or cable and replace if damaged.

• Check mounting hardware for proper tightness and re-torque if necessary.

• Gears, ratchet pivot point and shaft bushings must be kept lubricated with a thin film of oil or grease.

10454 O MLT4060-80M/K Operating Manual 29

Maintenance

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Operation

Take Line/Load In:

1. The cable must be securely fastened to the object being lifted and to the winch drum.

2. Always be sure that the cable and cable attachments are not damaged and are strong enough for the load. Ensure there is an adequate safety factor of at least three times the maximum load for all components used.

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.

Let Line/Load Out:

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. The gears and bushings of the winch must be kept lubricated. Apply a thin film of grease to the gear teeth, and oil the bushings as needed.

2. The ratchet pawl pivot point must be kept lubricated with a thin oil.

3. Do not get oil or grease on the friction discs.

Oil

Friction Discs

(No Grease/Oil)

Figure 18 - Locations for Oil or Grease on Winch

WINCH USE, OPERATION & MAINTENANCE - ELECTRIC

• Keep the winch free of dirt, oil, grease, water and other substances.

• Check all mounting bolts and make sure they are tightened to the recommended torque values. Replace any damaged fasteners.

Grease

00244

• Periodically check all connections to be sure they are tight and free of corrosion.

• Check the cable for visible damage every time the winch is operated. Examples of damage are: cuts, knots, mashed or frayed portions, and broken strands. Replace cable immediately if damaged. Failure to replace a damaged cable could result in breakage.

• Regularly check the brake for slippage or drift. This is detected visually when winch is under load. If winch drum continues to turn after controls are released, the brake may need to be replaced.

30 MLT4060-80M/K Operating Manual 10454 O

Maintenance

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• Periodically clean and grease the brake assembly. This will ensure proper performance and extend the life of the winch. If winch seems to labor or get excessively hot during the lowering of loads, the brake will need to be serviced or replaced.

• Check motor brushes periodically and replace when necessary.

Note: Only the motor brushes and brake assembly require periodic replacement.

Winch Preventive Maintenance Schedule

Maintenance Activity

Check Fasteners 

Check Electrical Connections 

Clean And Grease Brake Assembly 

Check Motor Brushes 

Visually Check Winch And Control  

Winch Mechanical Brake

The mechanical brake generates heat when loads are lowered and the wire cable is powered out. Care must be 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.

After First Operation

Before Each Use

Semi-Annually Or

After Each 25 Hours

Of Operation

JACK MAINTENANCE

The following procedures should be performed at least annually.

Side-Wind Models

• The internal gearing and bushings of the jack must be kept lubricated. Apply a small amount of automotive grease to the internal gearing by removing the jack cover, or if equipped, use a needle nose applicator or standard grease gun on the lubrication point found on the side of the jack near the crank. Rotate the jack handle to distribute the grease evenly.

• A lightweight oil must be applied to the handle unit at both sides of the tube.

• If equipped, the axle bolt and nut assembly of the caster wheel must also be lubricated with the same lightweight oil.

10454 O MLT4060-80M/K Operating Manual 31

Maintenance

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Top-Wind Models

• Apply a lightweight oil to the screw stem.

Oil Grease

Grease

Oil

Figure 19 - Applying Oil to Jacks

TRAILER WHEEL BEARINGS

The trailer axles are equipped with a grease zerk fitting to allow lubrication of the wheel bearings without the need to disassemble the axle hub. To lubricate the axle bearings, remove the small rubber plug on the grease cap, attach a standard grease gun fitting to the grease zerk fitting and pump grease into the fitting until new grease is visible around the nozzle of the grease gun. Use only a high quality grease made specifically for lubrication of wheel bearings. Wipe any excess grease from the hub with a clean cloth and replace the rubber plug when finished. The minimum recommended lubrication is every 12 months or 12,000 miles (19,312 km). More frequent lubrication may be required under extremely dusty or damp operating conditions.

Grease

Oil

00243

32 MLT4060-80M/K Operating Manual 10454 O

Section 5 - Troubleshooting

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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 engine operator’s manual for additional troubleshooting information or contact Generac Mobile Products Technical Service at 1-800-926-9768. Procedures that require in-depth knowledge or skills should be referred to a trained technician.

Table 1 - General Troubleshooting Guide

Problem

Low Oil Pressure Shutdown

High Coolant Temperature Shutdown

Overcrank Shutdown Fuel level low Check fuel level in tank.

Possible Cause Solution

Low oil level

Oil leaking from engine

Oil pressure sender

Low coolant level

Blockage in radiator

Leakage in coolant hoses, engine block, or water pump

Check oil level on dipstick. Add oil, if needed.

Visually inspect the engine for leaks. Restart unit and verify loss of pressure. Shut down immediately if pressure does not reach 5 psi (34 kPa) within five seconds.

Refer to engine operator’s manual to identify corrective action.

Add coolant if needed. Allow engine to cool, then check coolant level in radiator. Restart engine and check coolant temperature (on controller). Stop engine immediately if coolant temperature is 210°F (99°C) or more.

Check radiator shroud and ducting for blockage and remove any foreign matter.

Inspect for visible leaks. Check tension of water pump serpentine drive belt. Remove load on generator and restart engine. Check coolant temperature and shut engine down immediately if it starts to overheat. Refer to the engine operator’s manual for additional information on engine overheating.

Check fuel pump operation. Check air filter for blockage. Refer to engine operator’s manual for additional information.

Overspeed or Underspeed Shutdown

10454 O MLT4060-80M/K Operating Manual 33

Frequency setting incorrect Disconnect all loads and restart unit. Read frequency (Hz) in the

LCD window on controller. Frequency should read 60 Hz. If frequency is above 60 Hz, engine speed will need to be adjusted. Refer to the engine operator’s manual for throttle adjustment information.

Troubleshooting

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TROUBLESHOOTING THE LIGHTS

Table 2 - Troubleshooting the Lights Guide

Problem

Mast Lights Off but Ballast Indicators on Control Panel are On

Mast Lights Off and Ballast Indicators on Control Panel are Off

Possible Cause Solution

Mast light too hot

Faulty bulb connection

Bulb broken

Faulty junction box connections

Faulty coil cord connection

Faulty control box connections

Generator output incorrect

Low transformer output

Allow light to cool 10-15 minutes before restarting.

Check bulb is tight in socket.

Check for broken arc tube or outer bulb jacket, broken or loose components in bulb envelope or blackening/deposits inside tube.

Check connections inside mast junction box and each mast light housing/socket.

Check mast coil cord for damage and check cord connections inside control box.

Check connections inside control box and inside each ballast box.

Check incoming voltage to ballast by checking available voltage on GFCI receptacle. Incoming voltage should be 120V +/-5V. If voltage is incorrect, engine speed may need to be adjusted or generator may require service.

Voltage from transformer should read approximately 400VAC as light “strikes” (induces an arc), the drop and slowly rise back up to stabilize at 240-260VAC. On quick disconnect models, measure across junction box terminals when the light is unplugged. On hard wired models, remove mast junction box cover, and insert wire probes into connector blocks for light and ground. If proper voltage is not achieved, perform capacitor check to determine if the capacitor or coil needs to be replaced.

Mast Lights On but the Light Output is Low

Dirty fixture and/or lens

Bulb worn due to normal use

Faulty connections

Generator output incorrect

Low transformer output

Clean reflective surface inside fixture and both inside and outside surface of glass lens. Use mild soap and water to clean lens. Other chemicals may have an adverse effect on the glass.

Replace bulb.

Check the mast coil cord, mast junction box and mast light connections.

Check incoming voltage to ballast. Incoming voltage should be 120V +/-5V. In voltage is incorrect, engine speed may need to be adjusted or generator may require service.

34 MLT4060-80M/K Operating Manual 10454 O

Section 6 - Wiring Diagrams

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MAST LIGHT CONNECTIONS

MAST JUNCTION BOX WIRING

4-LIGHT

MAST LIGHT CONNECTIONS

4-LIGHT

00175

10454 O MLT4060-80M/K Operating Manual 35

Wiring Diagrams

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AC WIRING

TRANSFORMER 4

CAP 3

WT/BK OR BN

CAP 4

CAP 2 CAP 1

MAST CABLE

3 1

TRANSFORMER 3

3 1

TRANSFORMER 2

3 1

TRANSFORMER 1

TWIST

30 AMP

CB7

8KW UNITS

ONLY

30A

GND

BAR

GFCI

CB6

LED BOARD

34567

15 A

CB1 15 A

CB1

15 A

CB1 15 A

CB1

BK BK

GND

BAR

GND

GFCI

CB5

RD RD

20A

8KW UNITS ONLY

20A

MAIN

GEN

BAR

GND

34567

BAR

GND

90347_E_06.21.14

36 MLT4060-80M/K Operating Manual 10454 O

DC WIRING - MITSUBISHI ENGINE

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HOUR

VIO/YEL

BLK/WHT

VIO/YEL

RED

10 AMP

CIRCUIT

BREAKER

BLK

FUEL

PUMP

BLK/WHT

VI/YL

GRY/BLU

GRY/VIO

Wiring Diagrams

OIL

WARNING

PRESSURE

SWITCH (N.C.)

WARNING

OVERHEAT

SWITCH (N.O.)

VIO/YEL

RED/YEL

RED (PULL)

BLU (COM)

WHT (HOLD)

SOLENOID

BLK/YEL

RED/WHT

CONTROL

RESISTANCE

STARTER SWITCH

RD/VI

RED/YEL

ORG/YEL

AUX SWITCH

MAIN BREAKER

RD/VI

N/O

COM

N/C

RELAY

TIME DELAY

12V BATTERY

RED

STARTER

BLK

RED/VIO

ALTERNATOR

GLOW PLUGS

"TURN MAIN

WARNING LIGHT

BLK/WHT BLK

BREAKER OFF"

90340_C_04.23.13

10454 O MLT4060-80M/K Operating Manual 37

Wiring Diagrams

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DC WIRING - KUBOTA ENGINE

BK/WT

BK/YL

HOUR

BK/WT

VI/YL

RD/VI

VI/YL

YLBK

STARTER SWITCH

10 AMP

CIRCUIT

BREAKER

N/O

COM

FUEL

PUMP

OIL

WARNING

PRESSURE

SWITCH (N.C.)

GY/VI

GY/BL

WARNING

OVERHEAT

SWITCH (N.O.)

N/C

RELAY

TIME DELAY

12V BATTERY

VI/YL

RD/YL

(PULL)

(HOLD)

SOLENOID

RD/WT

BK/YL

GLOW PLUGS

RD/YL

OR/YL

AUX SWITCH

MAIN BREAKER

"TURN MAIN

WARNING LIGHT

STARTER

RD/VI

ALTERNATOR

RD/VI

BK/WT

BREAKER OFF"

90339_E_01.30.14

38 MLT4060-80M/K Operating Manual 10454 O

DC WIRING OPTIONS

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BATTERY CHARGER

EDISON PLUG

BLU

BRN

YEL/GRN

16/3

BATTERY

CHARGER

BLK

RED

Wiring Diagrams

25A

FUSE

BK/WT

RD/BK

12 V

BATTERY

RD/WT

ACC

STARTER SWITCH

8586

HEATED FUEL FILTER

NCCOM

87A

RD/VI

SPLICE

GND

BAR

RD/BK

NO-

TIME

DELAY

TO CNTRL

PANEL START

SOL WIRE

GND

BAR

TO MAIN

BREAKER AUX

SWITCH NC PIN

OR/YL1

ESTOP

RD/WT

BK/WT1

GND

BAR

RPM

SENSOR

BK/WT

12 V

BATTERY

BK/WT2

CIRCUIT

OR/YL2

20A

BREAKER

POSITIVE AIR SHUTDOWN 6-20KW

BK/WT

FLOAT

SWITCH

LOW FUEL SHUTDOWN

SOLENOID

PASS

OPT

RPM

PWR

GND

NCCOM

GND

BK1

SOL

PNK

TIME

DELAY

PASS

NO-

WT/VI

SPLICE

BATTERY

DISCONNECT

ALT CONFIG

MTB PIN 12

INTERIOR LIGHT BATTERY DISCONNECT

12 V

BATTERY

10A

FUSE

STARTER SWITCH

LIGHT

ACC

90323_K_06.04.14

10454 O MLT4060-80M/K Operating Manual 39

Wiring Diagrams

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DC WIRING OPTION - ELECTRIC WINCH

WINCH 2

BLK

CONTACTOR 2

BLK

WHT

DOWN

SWITCH 2SWITCH 1

CONTACTOR 2

BL YL

RELAY 2

PROX. AUX

BK BN GN

8586

BRN

BLK

87A

463

VIEWED FROM

WIRE INSERTION END

413

BLU

BLK

VIEWED FROM

WIRE INSERTION END

LIFT

PROX. SWITCH 2

6 7532

BRN

WINCH 1

BLK

DOWN

CONTACTOR 1

WHT

BL YL

BK BN GN

RELAY 1

PROX. AUX

86 85

BRN

BLK

87A

VI/YL

BLK

RED

BLK

RED

12 V

BATTERY

BLU

BLK

TILT

PROX. SWITCH 1

BRN

90463_B_07.16.14

40 MLT4060-80M/K Operating Manual 10454 O

TRAILER LIGHTS WIRING

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Wiring Diagrams

WT BN YL

PLUG

TRAILER

AMBER

MARKER

LAMP

SPLICE

MARKER

RED

SPADE

LAMP

SPADE

RING

RIGHT

TAIL/TURN

SPLICE

LAMP

SPLICE

LAMP

AMBER

MARKER

SPADE

RED

SPADE

LAMP

MARKER

SPADE

RDWTBK

LEFT

TAIL/TURN

LAMP

SPADE

90341_B_12.20.13

LAMP

PLATE

LICENSE

10454 O MLT4060-80M/K Operating Manual 41

Section 7 - Options & Accessories

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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.

• The heater is designed for all-night operation, however, 2-5 hours of heating just prior to starting is usually sufficient for proper engine starting.

• The unit must be level to maintain proper orientation of the heater while it is in operation.

• Use only an undamaged, outdoor rated, three-prong grounded 120VAC extension cord with a minimum amperage rating of 10A. Connect the cord to a properly grounded 120VAC, GFCI receptacle.

• Before starting the engine, unplug the extension cord from the power first, then unplug the heater cordset from the extension cord.

10454 O MLT4060-80M/K Operating Manual 43

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Generac Power Systems MLT4060M, MLT4060K, MLT4080M, MLT4080K Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual