Owner’s Manual
Light Tower
MLT3060MV • MLT3060KV• MLT3080KV
SAVE THIS MANUAL FOR FUTURE REFERENCE
Use this page to record important information about your Light Tower
Unit Model Number
Unit Serial Number
Engine Model
Number
Engine Serial
Number
Generator Model
Number
Generator Serial
Number
Record the information found on your unit data label on
this page. See unit serial number location (Unit Serial
Number Locations). The label plate is affixed to the
inside partition, to the left of the control panel console.
Engine and generator serial numbers are located on
separate data plates affixed to the engine and generator
respectively.
When contacting an Generac Mobile Products
Authorized Service Dealer about parts and service,
always supply the complete model number and serial
number of the unit.
Operation and Maintenance: Proper maintenance and
care of the Light Tower ensures a minimum number of
problems and keeps operating expenses at a minimum. It
is the operator’s responsibility to perform all safety
checks, to verify that all maintenance for safe operation is
performed promptly, and to have the equipment checked
periodically by a Generac Mobile Products Authorized
Service Dealer. Normal maintenance, service and
replacement of parts are the responsibility of the owner
or operator and, as such, are not considered defects in
materials or workmanship within the terms of the
warranty. Individual operating habits and usage may
contribute to the need for additional maintenance or
service.
WARNING
California Proposition 65. Engine exhaust and some
of its constituents are known to the state of California
to cause cancer, birth defects, and other reproductive
harm.
(000004)
WARNING
California Proposition 65. This product contains or
emits chemicals known to the state of California to
cause cancer, birth defects, and other reproductive
harm.
(000005)
ii
Owner’s Manual for MLT Light Tower
Table of Contents
Section 1: Introduction and Safety
Automatic Shutdown ........................................ 20
Introduction ..........................................................1
Light Operation .................................................. 20
Read This Manual Thoroughly ....................................1
Auxiliary Outlets ................................................ 21
How to Obtain Service .................................................1
Safety Rules .........................................................1
General Hazards ..................................................2
Explosion and Fire Hazards ................................2
Trailer Hazards .....................................................2
Wet Stacking ...................................................... 21
Engine Derating ................................................. 21
Shutting Down the Unit ..................................... 21
Lowering the Mast ............................................. 21
Lowering the Mast—Manually ..................................22
Electrical Hazards ................................................3
Towing the Unit ................................................. 22
Battery Hazards ...................................................3
Lifting the Unit ................................................... 23
Fuel Hazards ........................................................4
Engine Safety .......................................................4
Section 4:Maintenance
Operating Safety ..................................................4
Emissions Information ...................................... 25
Positioning the Unit .....................................................4
Daily Walk-Around Inspection ......................... 25
Starting the Unit ...........................................................4
Raising and Lowering the Mast ...................................5
Service Safety ......................................................5
General Maintenance ........................................ 25
Preparing for Service .................................................25
Cleaning the Unit .......................................................25
Towing Safety ......................................................6
Inspecting the Unit .....................................................25
Hitch and Coupling ......................................................6
Basic Maintenance Schedule ........................... 26
Running Lights ............................................................6
Wheels and Tires ........................................................6
Safe Towing Techniques .............................................6
Reporting Trailer Safety Defects ........................6
Section 2: General Information
Specifications ......................................................7
Winch Use, Operation and Maintenance ......... 28
Winch Mechanical Brake ...........................................28
Optional Lower Radiator Hose Heater Use and
Maintenance ....................................................... 29
Trailer Wheel Bearings ..................................... 29
Jack Maintenance .............................................. 29
Unit Dimensions .................................................9
Section 5:Troubleshooting
Unit Serial Number Locations ..........................10
General Troubleshooting .................................. 31
Component Locations .......................................11
Troubleshooting the Lights .............................. 32
Control Panel - MLT3060MV, MLT3060KV .......12
Control Panel Features and Functions ......................13
Control Panel - MLT3080KV ..............................14
Control Panel Features and Functions ......................15
Section 3:Operation
Light Tower Setup .............................................17
Prestart Checklist ..............................................18
Raising the Mast ................................................18
Starting the Unit .................................................19
Owner’s Manual for MLT Light Tower
Section 6:Wiring Diagrams
Mast Junction Box Wiring and Light
Connections ....................................................... 33
AC Wiring Diagram ............................................ 34
DC Wiring Diagram—Mitsubishi ...................... 35
DC Wiring Diagram—Kubota ............................ 36
DC Wiring Diagram—Electric Winch ............... 37
DC Wiring Diagrams for Optional Equipment . 38
iii
Trailer Lights Wiring ..........................................39
Section 7:Service Log
iv
Owner’s Manual for MLT Light Tower
Introduction and Safety
Section 1: Introduction and Safety
Introduction
Safety Rules
Thank you for purchasing a Generac Mobile Products LLC
product. This unit has been designed to provide high
performance, efficient operation, and years of use when
maintained properly.
The manufacturer cannot anticipate every possible
circumstance that might involve a hazard. The warnings in
this manual, and on tags and decals affixed to the unit are,
therefore, not all inclusive. If using a procedure, work
method or operating technique that the manufacturer does
not specifically recommend, verify that it is safe for others.
Also make sure the procedure, work method or operating
technique utilized does not render the equipment unsafe.
The information in this manual is accurate based on
products produced at the time of publication. The
manufacturer reserves the right to make technical updates,
corrections, and product revisions at any time without
notice.
Read This Manual Thoroughly
WARNING
Consult Manual. Read and understand manual
completely before using product. Failure to
completely understand manual and product
could result in death or serious injury.
(000100a)
If any section of the manual is not understood, contact your
nearest Generac Mobile Products Authorized Service
Dealer, or contact Generac Mobile Products LLC at 1-800926-9768, or Generac Mobile Products Technical Service at
1-800-926-9768 or www.generacmobileproducts.com
with any questions or concerns.
The owner is responsible for proper maintenance and safe
use of the equipment. Comply with regulations the
Occupational Safety and Health Administration (OSHA)
has established, or with equivalent standards. Also, verify
that the unit is applied, used, and maintained in accordance
with the manufacturer's instructions and recommendations.
Do nothing that might alter safe application/usage and
render the unit in noncompliance with the aforementioned
codes, standards, laws, and regulations.
Save these instructions for future reference. This manual
contains important instructions for the unit that should be
followed during setup, operation and maintenance of the
unit and battery. ALWAYS supply this manual to any
individual that will use this machine.
How to Obtain Service
When the unit requires servicing or repairs, contact a
Generac Mobile Products Authorized Dealer for assistance.
Service technicians are factory-trained and are capable of
handling all service needs. For assistance locating a dealer,
go to www.generacmobleproducts.com/parts-service/
find-service. When contacting a Generac Mobile Products
Authorized Dealer about parts and service, always supply
the complete model number and serial number of the unit
as given on its data decal located on the unit. Record the
model number and serial numbers in the spaces provided
on the inside front cover of this manual.
Owner’s Manual for MLT Light Tower
Throughout this publication, and on tags and decals affixed
to the unit, DANGER, WARNING, CAUTION and NOTE
blocks are used to alert personnel to special instructions
about a particular operation that may be hazardous if
performed incorrectly or carelessly. Observe them
carefully. Their definitions are as follows:
DANGER
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
(000001)
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
(000002)
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
(000003)
NOTE: Notes contain additional information important to
a procedure and will be found within the regular text of
this manual.
These safety alerts cannot eliminate the hazards that they
indicate. Common sense and strict compliance with the
special instructions while performing the action or service
are essential to preventing accidents.
1
Introduction and Safety
General Hazards
Explosion and Fire Hazards
DANGER
DANGER
Asphyxiation. Running engines produce
carbon monoxide, a colorless, odorless,
poisonous gas. Carbon monoxide, if not
avoided, will result in death or serious injury.
(000103)
Explosion and Fire. Fuel and vapors are
extremely flammable and explosive. Add fuel
in a well ventilated area. Keep fire and spark
away. Failure to do so will result in death
or serious injury.
(000105)
WARNING
Hearing Loss. Hearing protection is
recommended when using this machine.
Failure to wear hearing protection could
result in permanant hearing loss.
(000107)
WARNING
Risk of Fire. Unit must be positioned in a
manner that prevents combustible material
accumulation underneath. Failure to do so
could result in death or serious injury. (000147)
WARNING
Moving Parts. Keep clothing, hair, and
appendages away from moving parts. Failure
to do so could result in death or serious injury.
(000111)
WARNING
Hot Surfaces. When operating machine, do not
touch hot surfaces. Keep machine away from
combustibles during use. Hot surfaces could
result in severe burns or fire.
(000108)
WARNING
Risk of injury. Do not operate or service this machine
if not fully alert. Fatigue can impair the ability to service
this equipment and could result in death or serious
injury.
(000215)
WARNING
Risk of Fire. Hot surfaces could ignite
combustibles, resulting in fire. Fire could
result in death or serious injury.
(000110)
Trailer Hazards
WARNING
Trailer must be securely coupled to the hitch and the
chains correctly attached. Uncoupled or unchained
towing could result in death or serious injury.
(000233)
WARNING
Do not operate this unit while transporting. Doing so
could result in death or serious injury.
WARNING
Risk of burns. Allow engine to cool before
draining oil or coolant. Failure to do so could
result in death or serious injury.
(000139)
(000231)
WARNING
Crushing hazard. Verify unit is properly secured and
on level ground. An unsecured unit can suddenly roll
or move, causing death or serious injury.
(000234a)
WARNING
Property or Equipment Damage. Tighten wheel lug
nuts after first 50 miles to factory specifications.
Failure to do so could result in death, serious injury,
property or equipment damage.
(000235)
2
Owner’s Manual for MLT Light Tower
Introduction and Safety
Electrical Hazards
Battery Hazards
DANGER
DANGER
Electrocution. In the event of electrical accident,
immediately shut power OFF. Use non-conductive
implements to free victim from live conductor. Apply
first aid and get medical help. Failure to do so will
result in death or serious injury.
(000145)
DANGER
WARNING
Electrocution. Water contact with a power
source, if not avoided, will result in death
or serious injury.
(000104)
DANGER
Electrocution. Contact with bare wires,
terminals, and connections while generator
is running will result in death or serious injury.
(000144)
DANGER
Electrocution. Verify electrical system is
properly grounded before applying power.
Failure to do so will result in death or serious
injury.
(000152)
DANGER
Electrocution. Do not wear jewelry while
working on this equipment. Doing so will
result in death or serious injury.
(000188)
DANGER
Electrocution. DO NOT use the unit if
electrical cord is cut or worn through. Doing
so will result in death or serious injury.
(000263a)
Owner’s Manual for MLT Light Tower
Electrocution. Do not wear jewelry while
working on this equipment. Doing so will
result in death or serious injury.
(000188)
Explosion. Batteries emit explosive gases while charging.
Keep fire and spark away. Wear protective gear when
working with batteries. Failure to do so could result in
death or serious injury.
(000137a)
WARNING
Explosion. Do not dispose of batteries in a fire. Batteries
are explosive. Electrolyte solution can cause burns and
blindness. If electrolyte contacts skin or eyes, flush with water
and seek immediate medical attention.
(000162)
WARNING
Risk of burn. Do not open or mutilate batteries.
Batteries contain electrolyte solution which can
cause burns and blindness. If electrolyte contacts
skin or eyes, flush with water and seek immediate
(000163a)
medical attention.
WARNING
Environmental Hazard. Always recycle batteries at an
official recycling center in accordance with all local
laws and regulations. Failure to do so could result in
environmental damage, death or serious injury.
(000228)
Always recycle batteries in accordance with local laws and
regulations. Contact your local solid waste collection site
or recycling facility to obtain information on local recycling
processes. For more information on battery recycling, visit
the Battery Council International website at: http://
batterycouncil.org
3
Introduction and Safety
Fuel Hazards
Operating Safety
DANGER
Positioning the Unit
Explosion and fire.Fuel and vapors are extremely
flammable and explosive. No leakage of fuel is
permitted. Keep fire and spark away. Failure to do
so will result in death or serious injury.
(000192)
DANGER
Risk of fire. Allow fuel spills to completely dry
before starting engine. Failure to do so will
result in death or serious injury.
(000174)
• 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.
DANGER
High Voltage. Verify area above unit is clear
of overhead wires and obstructions. Contact
with high-voltage power lines will result in
death or serious injury.
(000260a)
WARNING
Burn hazard. Never operate lights with a
damaged or missing lens cover. Lamps are
hot and pressurized while in use. Unprotected
lamps can shatter, causing severe injury.
(000277)
• The area immediately surrounding the unit should
be dry, clean, and free of debris.
• Position and operate the unit on a firm, level
surface.
Engine Safety
Internal combustion engines present special hazards
during operation and fueling. Failure to follow the safety
guidelines described below could result in severe injury or
death. Read and follow all safety alerts described in the
engine operator's manual. A copy of this manual was
supplied with the unit when it was shipped from the factory.
• DO NOT run engine indoors or in an area with poor
ventilation. Make sure engine exhaust cannot seep
into closed rooms or ventilation equipment.
• If the unit is equipped with a frame grounding stud,
follow the National Electrical Code (NEC), state,
and local regulations when connecting.
Starting the Unit
DANGER
Electrocution. DO NOT use the unit if
electrical cord is cut or worn through. Doing
so will result in death or serious injury.
(000263a)
• DO NOT clean air filter with gasoline or other types
of low flash point solvents.
• DO NOT operate the unit without a functional
exhaust system.
• Shut the engine down if any of the following
conditions exist during operation:
• Noticeable change in engine speed.
• Loss of electrical output.
• Equipment connected to the unit overheats.
• Sparking occurs.
• Engine misfires or there is excessive engine/
generator vibration.
• Protective covers are loose or missing.
• Ambient air temperature is above 120°F (49°C).
4
WARNING
CAUTION
Equipment damage. Do not attempt to start or operate
a unit in need of repair or scheduled maintenance.
Doing so could result in serious injury, death, or
equipment failure or damage.
(000291)
Owner’s Manual for MLT Light Tower
Introduction and Safety
Service Safety
Raising and Lowering the Mast
WARNING
Electrocution. Do not set up or operate
this unit if severe weather is expected.
Lightning strikes can kill or cause severe injury
even if you are not touching the unit.
(000296)
WARNING
> 60 mph
Do not set up the unit if high winds
are expected. High winds can cause the
unit to tip or fall, causing severe injury
or machine damage.
(000297)
WARNING
Personal injury or equipment damage. Do not raise
or lower the mast while the unit is operating.
Doing so can break the lenses and cause the
lamps to shatter.
(000279)
WARNING
Personal Injury. Stop immediately if the mast hangs
up or the winch cable develops slack. Excess slack
could cause the mast to collapse, resulting in personal
injury or equipment damage.
(000265)
WARNING
Tipping hazard. Extend the outriggers and level the unit
before raising the mast. Keep the outriggers extended
while the mast is up. Failure to do so could cause the unit
to tip and fall and could result in death or serious injury.
This unit uses high voltage circuits capable of causing
serious injury or death. Only a qualified and licensed
electrician should troubleshoot or repair problems
occurring in this equipment.
• Before servicing the unit, verify the Control Power
switch and circuit breakers are in the OFF (O)
position, and the negative (-) terminal on the battery
is disconnected. DO NOT perform even routine
service (oil/filter changes, cleaning, etc.) unless all
electrical components are shut down.
• 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.
• DO NOT wash the unit with high pressure hoses,
power washers, or steam cleaners. Water may
collect in the unit, causing damage to electrical parts.
• Replace all missing and hard to read decals. Decals
provide important operating instructions and warn of
dangers and hazards.
• Wear heavy leather gloves when handling winch
cables. Never let cables slip through bare hands.
• Only use mild soap and water to clean the lens covers.
Other chemicals may damage the lens covers.
• Make sure slings, chains, hooks, ramps, jacks and
other types of lifting devices are attached securely
and have enough weight-bearing capacity to lift or
hold the equipment safely. Always remain aware of
the position of other people around you when lifting
the equipment.
(000266)
WARNING
Burn hazard. Lamps become extremely hot
while in use. Allow 10–15 minutes for cooling
before handling or lowering mast. Touching a
hot lens or fixture can cause severe burns.
(000278)
• Keep area around the unit clear of people while
raising and lowering the mast.
• ALWAYS lower the mast when not in use.
• The tower extends up to 25 ft (7.4 m). Make sure
area above trailer is open and clear of overhead
wires and obstructions.
• If for any reason any part of mast hangs up or
winch cable develops slack while raising or
lowering tower, STOP immediately! Contact a
Generac Mobile Products Authorized Service
Dealer.
• NEVER remove safety pin or pull mast locking pin
while tower is up.
Owner’s Manual for MLT Light Tower
5
Introduction and Safety
Towing Safety
Reporting Trailer Safety Defects
Towing a trailer requires care. Both the trailer and vehicle
must be in good condition and securely fastened to each
other to reduce the possibility of an accident. Some states
require that large trailers be registered and licensed.
Contact your local Department of Transportation office to
check on license requirements for your particular unit.
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.
Hitch and Coupling
• Verify the hitch and coupling on the towing vehicle
are rated equal to, or greater than, the trailer's
Gross Vehicle Weight Rating (GVWR).
• Verify the trailer hitch and the coupling are
compatible. Make sure the coupling is securely
fastened to the vehicle.
• DO NOT tow trailer using defective parts. Inspect
the hitch and coupling for wear or damage.
• Connect safety chains in a crossing pattern under
the tongue.
• Before towing the trailer, verify that the weight of
the trailer is equal across all tires. On trailers with
adjustable height hitches, adjust the angle of the
trailer tongue to keep the trailer as level as
possible.
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.
• Attach the breakaway cable to the rear bumper of
the towing vehicle.
Running Lights
Verify directional and brake lights on the trailer are
connected and working properly
Wheels and Tires
• Check trailer tires for wear and proper inflation.
• Verify wheel lug nuts are present and tightened to
the specified torque.
Safe Towing Techniques
• Practice turning, stopping and backing up in an
area away from heavy traffic prior to transporting
the unit.
• Maximum recommended speed for highway towing
is 45 mph (72 km/h). Recommended off-road
towing speed is 10 mph (16 km/h) or less,
depending on terrain.
• When towing, maintain extra space between
vehicles and avoid soft shoulders, curbs and
sudden lane changes.
6
Owner’s Manual for MLT Light Tower
General Information
Section 2: General Information
Specifications
DESCRIPTION
Engine
Make/Brand
Model
EPA Tier
Type
Horsepower - prime
Horsepower - standby
Operating Speed
Displacement
Cylinders
Fuel Consumption—100% Prime
Battery Type—Group Number
Battery Voltage
Battery Rating
Generator
Make/Brand
Model
Type, Insulation
Output
Output Voltage
Output Amperes 120V (240V)
Frequency Hz
Power Factor
Sound (23 ft at prime)
Weights
Dry Weight
Operating Weight
Capacities
Fuel Tank Volume
Usable Fuel Volume
Coolant (including engine)
Oil (including filter)
Maximum Run Time
AC Distribution
Circuit Breaker Size
Voltage Regulation
Voltages Available 1Ø
Lighting
Lighting Type
Ballast Type
Lumens
Coverage
UNITS
MLT3060MV
—
—
—
—
hp (kW)
hp (kW)
rpm
MITSUBISHI
KUBOTA
L3E-W461ML
D1005-E3BG1-MGM-1
4F
4F
Diesel, liquid cooled, 4-stroke
10.5 (7.8)
11.7 (8.7)
12.2 (9.1)
13.1 (9.8)
1800
1800
57.97 (0.95)
61.08 (1.00)
in3 (L)
qty
gph (Lph)
—
quantity per unit
CCA-hour
3
0.47 (1.78)
24
12V (1)
440
3
0.50 (1.89)
24
12V (1)
440
—
—
—
kW (kVA)
volts
amperes
Hertz
—
dB (A)
Marathon Electric
201CSA5411
Brushless, F
6.0 (6.0)
120/240, single phase
50 (25)
60
1 (1Ø)
70
Marathon Electric
201CSA5411
Brushless, F
6.0 (6.0)
120/240, single phase
50 (25)
60
1 (1Ø)
70
lbs (kg)
lbs (kg)
1694 (768)
1910 (886)
1707 (774)
1923 (872)
gal (L)
gal (L)
qt (L)
qt (L)
hours
30 (114)
30 (114)
4.5 (4.3)
3.8 (3.6)
64
30 (114)
30 (114)
4.8 (4.5)
5.4 (5.1)
60
amperes
—
—
30
Capacitor +/-6%
120, 240
30
Capacitor +/-6%
120, 240
—
—
—
Metal Halide
Coil & Core
440,000-462,000
5-7 (20,234 - 28,328)
Metal Halide
Coil & Core
440,000-462,000
5-7 (20,234 - 28,328)
1
2200 (988)
13
2” Ball
50
1
2200 (998)
13
2” Ball
50
acres (m2)
Trailer
Number of Axles
Capacity - Axle Rating
lbs (kg)
Tire Size
in
Hitch—Standard
—
Maximum Tire Pressure
psi
Specifications are subject to change without notice.
Owner’s Manual for MLT Light Tower
MLT3060KV
7
General Information
DESCRIPTION
Engine
Make/Brand
Model
EPA Tier
Type
Horsepower - prime
Horsepower - standby
Operating Speed
Displacement
Cylinders
Fuel Consumption—100% Prime
Battery Type—Group Number
Battery Voltage
Battery Rating
Generator
Make/Brand
Model
Type, Insulation
Output
Output Voltage
Output Amperes 120V (240V)
Frequency Hz
Power Factor
Sound (23 ft at prime)
Weights
Dry Weight
Operating Weight
Capacities
Fuel Tank Volume
Usable Fuel Volume
Coolant (including engine)
Oil (including filter)
Maximum Run Time
AC Distribution
Circuit Breaker Size
Voltage Regulation
Voltages Available 1Ø
Lighting
Lighting Type
Ballast Type
Lumens
Coverage
Trailer
Number of Axles
Capacity - Axle Rating
Tire Size
Hitch—Standard
Maximum Tire Pressure
Specifications are subject to change without notice.
8
UNITS
MLT3080kV
—
—
—
—
hp (kW)
hp (kW)
rpm
KUBOTA
D1105-E3BG
4F
Diesel, liquid cooled, 4-stroke
13.5 (10.1)
15.4 (11.5)
1800
68.53 (1.12)
in3 (L)
qty
gph (Lph)
—
quantity per unit
CCA-hour
3
0.70 (2.65)
24
12V (1)
440
—
—
—
kW (kVA)
volts
amperes
Hertz
—
dB (A)
Marathon Electric
201CSA5420
Brushless, F
8.0 (8.0)
120/240, single phase
66 (33)
66
1 (1Ø)
70
lbs (kg)
lbs (kg)
1729 (784)
1945 (882)
gal (L)
gal (L)
qt (L)
qt (L)
hours
30 (114)
30 (114)
4.8 (4.5)
5.4 (5.1)
43
amperes
—
—
30
Capacitor +/-6%
120, 240
—
—
—
acres (m2)
Metal Halide
Coil & Core
440,000-462,000
5-7 (20,234 - 28,328)
lbs (kg)
in
—
psi
1
2200 (988)
13
2” Ball
50
Owner’s Manual for MLT Light Tower
General Information
Unit Dimensions
B
A
C
D
E
004561
Figure 2-1. Unit Dimensions
MLT3060MV/KV,
MLT3080KV
A
B
C
D
E
117 in
(3 m)
111 in
(2.8 m)
25 ft
(7.6 m)
58 in
(1.5 m)
98 in
(2.5 m)
Specifications are subject to change without notice.
Owner’s Manual for MLT Light Tower
9
General Information
Unit Serial Number Locations
Refer to the illustration to locate the unit ID tag and
Vehicle Identification Number (VIN) tag on the unit.
Important information, such as the unit serial number,
model number, VIN and tire loading information are found
on these tags. Record the information from these tags so
it is available if the tags are lost or damaged. When
ordering parts or requesting assistance, you may be
asked to provide this information.
Unit ID Tag
Located on inside
of front panel
Manufactured by Generac Mobile Products LLC
(920) 361-4442
(800) 926-9768
Country of Origin
Model
Serial Number
Manufacturing Code
Weight (lbs/kg)
RPM/Frequency
Rating
1 ph. 1.0PF
VIN Tag
MANUFACTURED BY/FABRIQUE PAR: Generac Mobile Products LLC
GVWR/PNBV: 000KG (0000LBS)
GAWR / PNBE
TIRE / PNEU
3 ph. .8PF
3 ph. 1.0PF
KW
KVA
RIM / JANTE
DATE:
00/0000
COLD INF. PRESS./
PRESS. DE
TIRE AND LOADING INFORMATION
V
RENSEIGNEMENTS SUR LES
PNEUS ET LE CHARGEMENT
A
GONF A FROID - KPA(PSI/LPC) SGL / DUAL
Ins. Class
FOR ELECTRICAL EQUIPMENT
ONLY. POUR MATERIAL
ELECTRIQUE SEULEMENT.
209649
Form: SFC626B
The weight of cargo should never exceed 0000KG (0000LBS)
Le poids du chargement ne doit jamais depasser 0000KG (0000LBS)
EACH
AXLE
SEE OWNER’S
MANUAL FOR
ADDITIONAL
INFORMATION
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.
V.I.N./N.I.V.:
00000000000000000
XXX000
TRAILER
MODEL:
TYPE:
VOIR LE
MANUEL DE
L’USAGER
POUR
PLUS DE
RENSEIGNEMENTS
004553
Figure 2-2. Serial Number Locations
10
Owner’s Manual for MLT Light Tower
General Information
Component Locations
F
E
A
B
D
C
LEFT SIDE
C
K
G
H
J
I
RIGHT SIDE
004482
Figure 2-3. Component Locations
A
Engine Exhaust
E
Control Box
I
Outriggers
B
Mast Switch
F
Central Lifting Point
J
Engine Access
C
Forklift Pockets
G
Mast Rotation Knob
K
Radiator Access
D
Battery
H
Fuel Fill
— —
Owner’s Manual for MLT Light Tower
11
General Information
Control Panel - MLT3060MV, MLT3060KV
B
A
C
BALLAST INDICATOR LIGHTS
MAIN
BREAKER
240V
D
K
I
ON
TURN
MAIN
BREAKER
OFF
J
I
I
I
ON
ON
ON
O
ON
O
ON
O
O
MAST LIGHT SWITCHES
400W
120V
BREAKER
400W
Flagger Station Switches
OFF
GLOW
PLUG
RUN
GLOW PLUG
INDICATOR
E
START
120V
F
I
240V
DC
BREAKER
G
H
NEUTRAL BONDED TO FRAME
004548
Figure 2-4. Control Panel
12
Owner’s Manual for MLT Light Tower
General Information
Control Panel Features and Functions
(A) Main Circuit Breaker
(G) DC Circuit Breaker
This 240V (30A) breaker will disconnect power to the
lights and auxiliary outlets. It will also disable the starting
circuit if engine starting is attempted when the main
breaker is on.
Circuit breaker (10A) for the engine electrical system.
(H) 240V Twist-Lock Outlet
One circuit breaker is supplied for each light.
This 240V (30A) outlet supplies power for accessories
connected to the generator when the engine is running
and the main circuit breaker is switched to the ON (I)
position.
(C) Ballast Indicator Lights
(I) 120V GFCI Outlets
Indicates power from the ballast to each light.
This unit is equipped with one 120V (20A) GFCI outlet to
supply power for accessories connected to the generator
when the engine is running and the main circuit breaker
is switched ON (I).
(B) Light Switches
(D) Engine Starting Switch
Keyed switch operates glow plugs, starts and stops
engine.
(E) Glow Plug Indicator
Indicates operation of the engine glow plugs (Mitsubishi
engines only).
(F) Engine Hour Meter
Keeps track of engine hours for service.
Owner’s Manual for MLT Light Tower
(J) 120V Breaker
This 120V (20A) circuit breaker is supplied for the 120V
GFCI duplex outlets.
(K) 120V Breaker
This light indicates that the main circuit breaker must be
opened (switched off) before starting the engine.
13
General Information
Control Panel - MLT3080KV
A
B
D
C
BALLAST INDICATOR LIGHTS
MAIN
BREAKER
240V
K
I
J
ON
ON
TURN
MAIN
BREAKER
OFF
120V
BREAKER
I
I
I
E
ON
ON
O
ON
O
ON
O
O
MAST LIGHT SWITCHES
120V
BREAKER
OFF
GLOW
PLUG
I
240V
BREAKER
RUN
START
F
H
120V
I
120V
ON
ON
O
G
240V
DC
BREAKER
NEUTRAL BONDED TO FRAME
004554
Figure 2-5. Control Panel
14
Owner’s Manual for MLT Light Tower
General Information
Control Panel Features and Functions
(A) Main Circuit Breaker
(G) DC Circuit Breaker
This 240V (30A) breaker will disconnect power to the
lights and auxiliary outlets. It will also disable the starting
circuit if engine starting is attempted when the main
breaker is on.
Circuit breaker (10A) for the engine electrical system.
(H) 120V GFCI Outlets
One circuit breaker is supplied for each light.
This unit is equipped with one 120V (20A) GFCI outlet to
supply power for accessories connected to the generator
when the engine is running and the main circuit breaker
is switched ON (I)
(C) Ballast Indicator Lights
(I) 240V Twist-Lock Outlet
Indicates power from the ballast to each light.
(D) 240V Breaker
This 240V (30A) outlet supplies power for accessories
connected to the generator when the engine is running
and the main circuit breaker is switched to the ON (I)
position.
This 240V (30A) circuit breaker is supplied for the 240V
twist-lock receptacle.
(J) 120V Breaker
(E) Engine Starting Switch
This 120V (20A) circuit breaker is supplied for the 120V
GFCI duplex outlets.
Keyed switch operates glow plugs, starts and stops
engine.
(K) Circuit Breaker Indicator Light
(F) Engine Hour Meter
This light indicates that the main circuit breaker must be
opened (switched off) before starting the engine.
(B) Light Switches
Keeps track of engine hours for service.
Owner’s Manual for MLT Light Tower
15
General Information
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16
Owner’s Manual for MLT Light Tower
Operation
Section 3: Operation
Light Tower Setup
H
DETAIL C
F
J
DETAIL D
D
DETAIL G
A
B
C
D
E
G
DETAIL H
004556
Figure 3-1. Set Up Outriggers and Jacks
DANGER
High Voltage. Verify area above unit is clear
of overhead wires and obstructions. Contact
with high-voltage power lines will result in
death or serious injury.
(000260a)
WARNING
> 60 mph
Do not set up the unit if high winds
are expected. High winds can cause the
unit to tip or fall, causing severe injury
or machine damage.
(000297)
1. For maximum light coverage, position the unit at
ground level or in a spot higher than the area being
illuminated by the lamps.
NOTE: The mast extends up to 25 ft (7.4 m).
Owner’s Manual for MLT Light Tower
2. See Figure 3-1. Place the unit on firm ground that
is relatively flat (less than 5° slope), and 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 (B) and
rotate the jack 90°. Install the locking pin. Rotate
the jack handle clockwise to raise the trailer tongue
off the towing vehicle.
4. A grounding stud (C) is located on the frame of the
trailer near the trailer tongue. For grounding
requirements, follow National Electrical Code
(NEC), state, and local regulations.
5. Pull the locking pins (D) on the outriggers (E) and
pull each outrigger out until the spring loaded
locking pin snaps back into place. Pull the locking
pin on each outrigger jack and rotate each jack 90°
so the jack pad is facing down and the spring
loaded locking pin snaps back into place.
6. Pull the locking pin on the rear jack (F) and rotate it
90º until the spring loaded pin snaps back into
17
Operation
place. Turn the jack handle clockwise to start
leveling the trailer.
7. Adjust all four jacks by rotating their handles
clockwise until they are firmly in contact with the
ground (G).
8. Before raising the mast, it may be necessary to
adjust the lamps. The lamps may be adjusted up,
down, left or right by loosening the wing nuts on the
trunnion (H) and aiming the lamps in the desired
direction. Tighten the hardware completely and
make sure the lamps are connected to the junction
box (J).
Prestart Checklist
Raising the Mast
1. Set up and level the unit. See Light Tower Setup.
DANGER
Electrocution. DO NOT use the unit if
electrical cord is cut or worn through. Doing
so will result in death or serious injury.
(000263a)
WARNING
Tipping hazard. Extend the outriggers and level the unit
before raising the mast. Keep the outriggers extended
while the mast is up. Failure to do so could cause the unit
to tip and fall and could result in death or serious injury.
(000266)
Before starting the unit, all items in the prestart checklist must be completed. This checklist applies to both
manual and remote starting of the unit.
WARNING
Consult Manual. Read and understand manual
completely before using product. Failure to
completely understand manual and product
could result in death or serious injury.
(000100a)
 Verify all maintenance procedures are up to date. For
more information, refer to General Maintenance and
Basic Maintenance Schedule.
 The unit must be level.
 The unit must be dry. Look for water inside or near
the unit; dry if needed.
DETAIL B
A
STOP
 For grounding requirements, follow the National
Electrical Code (NEC), state, and local regulations.
 Verify the Control Power switch is in the OFF (O)
position.
DETAIL C
 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
C
B
D
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.





Verify battery connections are secure.
Turn the battery disconnect switch on, if equipped.
Check the engine fan belt tension and condition.
Check the engine fan belt guard.
Check the engine exhaust system for loose or rusted
components.
 Verify all covers are in place and secure.
18
004557
Figure 3-2. Raising the Mast
Owner’s Manual for MLT Light Tower
Operation
2. See Figure 3-2. Check both sets of mast cables for
excessive wear or damage. Verify the cables are
properly centered in each pulley (A). Check the
electrical cord for damage.
NOTE: If the red light on the control panel TURN MAIN
BREAKER OFF is illuminated when the key is turned to
the START position, the breaker is closed (switched on)
and must be turned OFF/O.
3. Press and hold the winch control toggle switch (B)
upward to telescope the mast to the desired height.
Extend the mast slowly, verifying that the coiled
electrical cord is extending at the top sections of
the mast. Do not extend past the colored mark (C).
IMPORTANT NOTE: Contact a Generac Mobile Products Authorized Service Dealer immediately if the
mast hangs up or the winch cable develops slack.
I
I
I
I
O
O
O
O
4. The mast can be rotated by loosening the mast
rotation knob at the bottom of the mast (D). Turn
the mast until the lights face in the desired direction
and then tighten the knob.
003791
Figure 3-3. Circuit Breakers in OFF (O) Position
WARNING
Tipping hazard. Do not extend the mast beyond the
colored mark on the second mast section. The unit
can become unstable and tip or fall, causing injury.
(000262)
2. See Figure 3-4. Turn the key on the Engine Start
switch to the right 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.)
WARNING
Personal Injury. Stop immediately if the mast hangs
up or the winch cable develops slack. Excess slack
could cause the mast to collapse, resulting in personal
injury or equipment damage.
(000265)
OFF
GLOW
PLUG
RUN
START
WARNING
Personal injury or equipment damage. Do not raise
or lower the mast while the unit is operating.
Doing so can break the lenses and cause the
lamps to shatter.
(000279)
003792
Figure 3-4. Activate Glow Plug
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.
3. See Figure 3-5. Turn the key to the right START
position and hold it until the engine cranks and
starts running.
CAUTION
1. See Figure 3-3. Verify the main circuit breaker and
individual circuit breakers for each of the lights are
OFF (O).
Equipment Damage. Do not continuously crank
engine for more than ten seconds. Doing so will lead
to overdischarge of batteries and starter seizure.
(000230)
WARNING
NOTE: For cold weather conditions, refer to the engine
operator’s manual for appropriate glow plug interval.
Equipment Damage. Never start the engine with
circuit breakers switched on. Any load connected
to the generator at start up will cause severe
damage or destroy the generator.
(000368)
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
Owner’s Manual for MLT Light Tower
19
Operation
“OFF” position to reset the oil pressure timer before
attempting to restart the engine.
Light Operation
WARNING
Burn hazard. Never operate lights with a
damaged or missing lens cover. Lamps are
hot and pressurized while in use. Unprotected
lamps can shatter, causing severe injury.
(000277)
OFF
GLOW
PLUG
RUN
1. Verify the unit is on and running smoothly.
START
003793
Figure 3-5. Crank Engine
2. See Figure 3-7. Switch the main circuit breaker (A)
ON (I).
3. Switch the individual circuit breakers for the lights
(B) ON (I), one at a time.
4. The ballast indicator lights (C) will turn on and
continue to get brighter as the lights warm up, and
then remain on. This confirms power is coming
from the ballasts to the lights.
4. See Figure 3-6. Release the key, it will move to the
RUN position.
A
B
C
BALLAST INDICATOR LIGHTS
OFF
GLOW
PLUG
MAIN
BREAKER
240V
I
RUN
ON
TURN
MAIN
BREAKER
OFF
I
I
I
ON
ON
ON
O
ON
O
ON
O
O
MAST LIGHT SWITCHES
400W
120V
BREAKER
400W
Flagger Station Switches
OFF
GLOW
PLUG
RUN
GLOW PLUG
INDICATOR
START
START
120V
240V
DC
BREAKER
003794
NEUTRAL BONDED TO FRAME
Figure 3-6. Release Key
004477
5. Once the engine is running, allow it to reach
normal operating temperature before switching on
any loads.
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 main
circuit breaker to the OFF position to reset the unit after
the cause of shutdown has been determined.
20
Figure 3-7. Light Switches and Breaker
NOTE: If an indicator light does not turn on, see
Troubleshooting or contact a Generac Mobile Products
Authorized Service Dealer.
NOTE: 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
ten minutes before they can be switched on again.
NOTE: The light tower uses four 1000W or 1050W
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.
Owner’s Manual for MLT Light Tower
Operation
Engine Derating
WARNING
Burn hazard. Lamps become extremely hot
while in use. Allow 10–15 minutes for cooling
before handling or lowering mast. Touching a
hot lens or fixture can cause severe burns.
(000278)
Auxiliary Outlets
See Figure 3-8. Depending upon the model, the control
panel is equipped with one or two 120V GFCI (A) and a
240V Twist Lock (B) outlet 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 ON (I).
NOTE: Do not pull more than 1000W from each outlet
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 outlets and wait 10 minutes for the bulbs to
cool before turning them back on.
With all of the lights off, the full generator output may be
used with the 240V twist-lock outlet.
BREAKER
All units are subject to derating for altitude and
temperature. Derating reduces the available power for
operating tools and accessories connected to the outlets.
For every increase in 1000 ft (305 m) of elevation, engine
performance for this unit typically drops between 2% and
4%. Also, engine performance decreases about 1% for
every 10ºF (5.6ºC) increase in ambient air temperature
over 72ºF (22ºC).
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 shutdown will not create any
hazards by accidentally turning off equipment that needs
to remain running (pumps, compressors, lights, etc.).
1. Remove all loads from the outlets.
2. See Figure 3-9. Switch the individual circuit
breakers for each light OFF (O).
3. Switch the main circuit breaker OFF (O).
4. Turn the engine start switch to STOP.
NOTE: For extended storage time, disconnect the
battery. For extended storage requirements, refer to the
engine operator’s manual.
B
BREAKER
240V
BREAKER
A
I
120V
O
OFF
GLOW
PLUG
240V
I
O
I
O
I
O
I
O
RUN
START
NEUTRAL BONDED TO FRAME
004478
Figure 3-8. Auxiliary Outlets
004550
Figure 3-9. Shutting Down the Unit
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.
Lowering the Mast
WARNING
Burn hazard. Lamps become extremely hot
while in use. Allow 10–15 minutes for cooling
before handling or lowering mast. Touching a
hot lens or fixture can cause severe burns.
(000278)
1. Shut down the lights and engine. See Shutting
Down the Unit.
2. If the trailer is going to be moved, it is
recommended that the mast is turned so the lights
face toward the back of the unit. To rotate the mast:
a. Loosen the mast rotation knob.
Owner’s Manual for MLT Light Tower
21
Operation
b. Rotate the mast until the white arrows are
aligned and the metal stop tabs are touching.
The winch and lights should be facing toward
the back of the unit.
c.
Tighten the mast rotation knob.
3. Press and hold the winch control toggle switch
downward to collapse the mast to its lowest
position. Verify the electrical cord does not get
caught in, or pinched by, the mast while it is being
lowered.
WARNING
Personal Injury. Stop immediately if the mast hangs
up or the winch cable develops slack. Excess slack
could cause the mast to collapse, resulting in personal
injury or equipment damage.
(000265)
IMPORTANT NOTE: Contact a Generac Mobile
Products Authorized Service Dealer immediately if
the mast hangs up or the winch cable develops
slack.
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.
NOTE: Generac Mobile Products strongly recommends
that the lights be removed from the mast and stowed for
transportation.
Lowering the Mast—Manually
WARNING
Burn hazard. Lamps become extremely hot
while in use. Allow 10–15 minutes for cooling
before handling or lowering mast. Touching a
hot lens or fixture can cause severe burns.
(000278)
NOTE: 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” allen head wrench (D) into the sleeve
bearing.
5. Rotate the wrench counterclockwise 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, install the
winch motor assembly, securing it with the screws.
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.
Verify locking pin snaps into place.
2. Raise the outrigger jacks completely and release
the jack locking pin to swing the jacks up into the
travel position. Verify 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 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, lubricate
the grease fittings located on the leveling jacks.
Refer to Jack Maintenance. For maintenance
interval information, refer to Basic Maintenance
Schedule.
5. Connect any trailer wiring to the tow vehicle. Check
for proper operation of the directional and brake
lights.
A
D
7. Verify the doors and enclosure are properly
latched.
B
C
A
Figure 3-10. Winch Assembly
22
6. Verify the mast cradle locking pin is in place.
004558
8. If driving 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.
Owner’s Manual for MLT Light Tower
Operation
10. See Figure 3-11. Check the wheel lugs. Tighten or
replace any lugs that are loose or missing. If a tire
has been removed for axle service or replaced,
tighten the lugs, in the order shown, to the
following specifications:
A
B
1
4
3
2
5
003754
Figure 3-11. Tightening Wheel Lugs
C
Figure 3-12. Lifting Point
004490
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.
11. Maximum recommended speed for highway towing
is 45 mph (72 km/h). Recommended off-road
towing speed is not to exceed 10 mph (16 km/h) or
less, depending on the terrain.
Lifting the Unit
Follow these steps to prepare the unit for lifting:
1. Verify the equipment being used to lift the unit is in
good condition and has sufficient capacity. For
approximate weights, refer to Specifications.
2. See Figure 3-12. Close and lock all hoods and
doors and stow the lights as shown.
3. Verify the cradle locking pin is in place.
4. When lifting the light tower and trailer, attach any
slings, chains or hooks directly to the central lifting
eye (A).
5. Always remain aware of people and objects around
the unit while preparing, maneuvering, and lifting
the unit.
6. Use the upper (B) or lower forklift pockets (C) with
care. Approach the unit as perpendicular as
possible to avoid any damage to the unit. Make
sure the mast winch handles or any other
obstructions are clear of the forklift tines before
lifting.
Owner’s Manual for MLT Light Tower
23
Operation
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24
Owner’s Manual for MLT Light Tower
Maintenance
Section 4: Maintenance
Emissions Information
4.
For warranty information, please refer to the diesel
engine manual supplied with this unit.
Daily Walk-Around Inspection
Perform a walk-around inspection of the unit every day
before starting the unit. Look for conditions that could
hinder performance or safety, such as (but not limited to):
•
•
•
•
Oil, coolant and fuel leakage
Blocked vents
Attach a “Do Not Start” sign to the control panel.
This will notify everyone that the unit is being
serviced and will reduce the chance of someone
inadvertently trying to start the unit.
Cleaning the Unit
Always clean the Light Tower after each use to remove
dust, grease, mud, or spilled fuel or oil. Use soft, clean
rags to wipe the cabinet exterior and control panel. Lowpressure compressed air (less than 40 PSI [276 kPa])
can also be used to remove dust and debris from the
cabinet interior.
This unit contains sensitive electronic components that
can be damaged by high pressure and heat. Therefore:
Loose or missing hardware
Loose or broken electrical connections.
Inspect the fan belt for cracks, fraying, or stretching. Verify
the belt is properly seated in the pulley grooves. Replace
the belt according to the manufacturer’s recommendations.
CAUTION
Equipment Damage. Failure to perform a daily
inspection could result in damage to the unit.
(000306)
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. DO NOT perform
routine service (oil and filter changes, cleaning, etc.)
unless all electrical components are shut off.
• Do not wash the unit with a high pressure hose or
power washer.
• Do not 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.
Inspecting the Unit
• 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.
• Verify winch cables are in good condition and
centered on each pulley. DO NOT use a cable that
is kinked or starting to unravel.
• See Figure 4-1. Verify mast cable is correct.
Regular maintenance will improve performance and
extend engine/equipment life. Generac Mobile Products
LLC recommends that all maintenance work be
performed by a Generac Mobile Products Authorized
Service Dealer. Regular maintenance, replacement or
repair of the emissions control devices and systems may
be performed by any repair shop or person of the owner’s
choosing. However, to obtain emissions control warranty
service free of charge, the work must be performed by a
Generac Mobile Products Authorized Service Dealer or
authorized engine dealer depending on the repair. See
the emissions warranty.
Preparing for Service
Before servicing the unit, always follow the instructions
listed below.
1.
Verify the key switch is in the OFF position.
2.
Verify the circuit breakers are switched OFF (O).
3.
Disconnect the negative (–) terminal on the battery.
Owner’s Manual for MLT Light Tower
004559
Figure 4-1. Proper Mast Cable Routing
25
Maintenance
• Verify 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.
Basic Maintenance Schedule
• Check the coolant level daily by inspecting the
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.
level in coolant overflow jug located near the
radiator. Refer to the engine operator’s manual for
coolant recommendations and proper mixture.
Normal operating level is between the ‘full’ and
‘add’ markings on the overflow jug.
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 a Generac Mobile Products Authorized Service
Dealer.
• Verify the wheel lugs are present and properly
tightened. Refer to Towing Safety.
• AFTER ENGINE IS STOPPED AND COMPLETELY
COOL, coolant may be added directly to the coolant
overflow jug.
• Check the oil level daily. Refer to the engine
operator’s manual for the appropriate oil specification.
Verify the oil is correct for 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.
• If the unit is connected to a remote start or transfer
switch, make sure the remote switch is also off and
tagged.
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.
26
Owner’s Manual for MLT Light Tower
Maintenance
Table 4-1. Basic Maintenance Guide (Mitsubishi)
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

50
Hours
Fuel tank - drain water

Check air cleaner

250
Hours
Replace engine oil and oil filter
*
Belt and belt tension - inspect and adjust

Replace fuel filter
Drain and clean fuel tank
400
Hours
500
Hours
1000
Hours

**
Check glow plugs

Lubricate leveling jacks

Bolts and nuts on the engine - retighten
*
Replace heated fuel filter (if equipped)

Inspect engine starting battery

*
**
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
dusty conditions, clean the fuel tank as often as necessary.
Owner’s Manual for MLT Light Tower
27
Maintenance
Table 4-2. Basic Maintenance Guide (Kubota)
ITEM
Check oil level
Check coolant level
Check fuel level
Check tire pressure
Check all electrical connections
Inspect radiator fins for debris, clean as required
Inspect light tower winch for proper operation
Check fuel pipes and clamp bands
Clean air cleaner element
Clean fuel filter
Check fan belt tightness
Drain water separator
Check radiator hoses and clamp bands
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
*
**
50
100
200
400
500
1
Hours Hours Hours Hours Hours 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 and
Maintenance
• 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.
• Periodically check all connections to be sure they
are tight and free of corrosion.
• Check the cable for visible damage every time the
• 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 Mechanical Brake
winch is operated. Examples of damage are: cuts,
knots, crushed or frayed portions, and broken
strands. Replace cable immediately if damaged.
Failure to replace a damaged cable could result in
breakage.
The mechanical brake generates heat when loads are
lowered and the wire cable is powered out. Avoid
overheating the mechanical brake.
• Regularly check the brake for slippage or drift. This
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.
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.
28
DAILY
Whine or chatter associated with a new mechanical
brake is normal and typically disappears with use.
Owner’s Manual for MLT Light Tower
Maintenance
Table 4-3. Winch Preventative Maintenance Schedule
Maintenance Activity
After First
Operation
Before Each Use
Semi-Annually
Check Fasteners


Check Electrical Connections


Clean And Grease Brake Assembly

Check Motor Brushes

Visually Check Winch And Control

Optional Lower Radiator Hose
Heater Use and Maintenance
The following points should be followed when operating a
unit equipped with a lower radiator hose heater.
IMPORTANT NOTE: Improper use of the lower radiator
hose heater could result in serious personal injury.
•
•
•
•
•
Verify that cooling system is full of a proper mixture
of water and engine coolant before each heater
use.
Heater is designed for all-night operation; however, 2-5 hours of heating just prior to starting is
usually sufficient for proper engine starting.
When heater is in operation, unit must be parked
in a level position to maintain the proper orientation
of the heater.
Use only an undamaged extension cord, outdoors
rated, three-prong grounded 120VAC cord with a
minimum amperage rating of 10A. Connect to
properly grounded 120VAC, GFCI outlet only.
Before starting the engine, unplug extension cord
from power first; then unplug heater cordset from
extension cord.


Jack Maintenance
The following procedures should be performed at least
annually: For side-wind models, the internal gearing and
bushings of the jack must be kept lubricated.
• Apply a small amount of automotive grease (A) 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 (B) must be applied to the handle
unit at both sides of the tube for side-wind models.
• If equipped, the axle bolt and nut assembly of the
caster wheel must also be lubricated with the same
lightweight oil.
• For top-wind models, apply a lightweight oil to the
screw stem.
Trailer Wheel Bearings
The light tower is 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.
Owner’s Manual for MLT Light Tower
29
Maintenance
A
B
A
B
A
B
B
B
002306
002306
Figure 4-2. Jack Maintenance
30
Owner’s Manual for MLT Light Tower
Troubleshooting
Section 5: Troubleshooting
General Troubleshooting
Some of the more common problems are listed in the
table below. This information is intended to be a check or
verification that simple causes can be located and fixed.
It does not cover all types of problems. Refer to the OEM
engine operator’s manual for additional troubleshooting
information. Procedures that require in-depth knowledge
or skills should be referred to a Generac Mobile Products
Authorized Service Dealer.
WARNING
Risk of burns. Allow engine to cool before
draining oil or coolant. Failure to do so could
result in death or serious injury.
(000139)
Table 5-1. General Troubleshooting Guide
Problem
Low oil pressure
shutdown
High coolant
temperature shutdown
Unit cranks, but will not
start
Possible Cause
Solution
Low oil level
Verify oil level on dipstick. Add oil, if needed.
Oil leaking from engine
Visually inspect the engine for leaks.
Oil pressure switch failure
Refer to OEM engine operator’s manual to identify corrective
action.
Low coolant level
Add coolant if needed. Allow engine to cool, then check coolant
level in radiator. Restart engine and check coolant temperature.
Stop engine immediately if coolant temperature is 210°F (99°C)
or more.
Blockage in radiator
Inspect radiator shroud and ducting for blockage and remove
any foreign matter.
Leakage in coolant hoses,
engine block, or water
pump
Inspect for visible leaks. Verify tension of water pump serpentine
drive belt.
Remove load on generator and restart engine. Verify coolant
temperature and shut engine down immediately if it starts to
overheat. Refer to the OEM engine operator’s manual for
additional information on engine overheating.
Fuel level low
Check fuel level in tank.
Verify fuel pump operation.
Restricted air filter
Inspect air filter for blockage.
Refer to OEM engine operator’s manual for additional
information.
If problems persist, contact Generac Mobile Products at 1-800-926-9768 for assistance.
Owner’s Manual for MLT Light Tower
31
Troubleshooting
Troubleshooting the Lights
WARNING
Burn hazard. Lamps become extremely hot
while in use. Allow 10–15 minutes for cooling
before handling or lowering mast. Touching a
hot lens or fixture can cause severe burns.
(000278)
IMPORTANT NOTE: Only a qualified electrician
should troubleshoot or repair electrical problems
occurring in this equipment. Contact Generac Mobile
Products Technical Service at 1-800-926-9768 for
assistance if you have any questions, or if problems
persist.
WARNING
Electrocution. Potentially lethal voltages are generated
by this equipment. Render the equipment safe before
attempting repairs or maintenance. Failure to do so
could result in death or serious injury.
(000187)
Problem
Mast Lights Off, but
Ballast Indicators
on Control Panel
are On.
Mast Lights Off,
and Ballast
Indicators on the
Control Panel are
Off.
Mast Lights On But
the Light Output is
Low
32
Possible Cause
Solution
Light fixture is too hot.
Allow light to cool 10-15 minutes before restarting.
Faulty lamp connection.
Check that the lamp is tight in the socket.
Lamp broken
Check for broken arc tube or outer lamp jacket, broken or loose
components in lamp envelope, or blackening/deposits inside tube.
Loose lighting
connections
Check the connections inside the mast junction box and each mast light
housing/socket.
Damaged or loose
electrical cord
Loose lighting
connections
Check the mast electrical cord for damage and check the cord connections
inside the control box.
Generator output
incorrect.
Check the incoming voltage to the ballast by checking the available voltage
on the GFCI receptacle. Incoming voltage should be 120V +/- 5V. If voltage
is incorrect, the engine speed may need to be adjusted or generator may
require service.
Low transformer output.
The voltage from the transformer should read approximately 400VAC as
the light “strikes” (induces an arc), then drop and slowly rise back up to
stabilize at 240-260VAC. On hard wired models,
remove the mast junction box cover and insert the wire probes into the
connector blocks for the light and ground. If proper voltage is not achieved,
perform capacitor check to determine if the capacitor or coil needs
to be replaced.
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.
Fixture and/or lens is
dirty.
Check the connections inside the control box and inside each ballast box.
Lamp worn due to
normal use
Replace lamp.
Damaged or loose
electrical connections
Check the mast coil cord, mast junction box and mast light connections.
Generator output
incorrect.
Check the incoming voltage to the ballast. Incoming voltage should be
120V +/-5V. If the voltage is incorrect, the engine speed may need to be
adjusted or the generator may require service.
Low transformer output
The voltage from the transformer should read approximately 400VAC as the
light “strikes” (induces an arc), then drop and slowly rise back up to stabilize
at 240-260VAC. On hard wired models, remove the mast junction box cover
and insert the wire probes into the connector blocks for the light and ground.
If proper voltage is not achieved, perform capacitor check to determine if the
capacitor or coil needs to be replaced.
Owner’s Manual for MLT Light Tower
Wiring Diagrams
Section 6: Wiring Diagrams
Mast Junction Box Wiring and Light Connections
2
1
4
3
00768
Owner’s Manual for MLT Light Tower
33
TO
GND
BAR
TO
GND
BAR
WT
GN
N
1
10
9
8
7
6
5
4
3
2
WT
WT
WT
WT
WT
WT
WT
RD
BK
RD
BK
GFCI
GFCI
BK
RD
X
Y
GN
WT
8KW UNITS ONLY
20A
CB5
20A
CB6
15 A
BK
30A
15 A
GEN
RD
CB7
TO
GND
BAR
TO
GND
BAR
Z
G
GN
TO
GND
BAR
BK
RD
BK
RD
1
12
11
10
9
8
7
6
5
4
3
2
YL
BK
BL
RD
RD
RD
RD
RD
RD
GY
RD
GY
YL
BL
WT
RD
BK
BK
BK
BK
BK
BL
BK
BL
BK
LED BOARD
CAP 2
MAST CABLE
4
3
2
1
.
1
2
.
3
CAP 1
TRANSFORMER 1
RD
RD
BK
BL
BK
RD
YL
.
2
.
3
TRANSFORMER 2
1
CAP 4
WT
BK
RD
GN
YL
BL
WT/BK OR BN
BK
RD
YL
30 AMP
TWIST
GY
MAIN
BK
CB1
BK
RD
15 A
CB1
RD
BK
CB1
BK
RD
15 A
CB1
RD
4
2
3
1
WT
WT
3
2
1
4
1
.
2
.
3
CAP 3
TRANSFORMER 3
RD
BK
GN
BK
GN
WT
BK
GN
BK
GN
WT
BK
BL
BK
RD
YL
34
GY
8KW UNITS
ONLY
.
.
3
TRANSFORMER 4
2
BK
RD
YL
1
Wiring Diagrams
AC Wiring Diagram
90347_E_06.21.14
Owner’s Manual for MLT Light Tower
"TURN MAIN
BREAKER OFF"
WARNING LIGHT
BLK
BLK/YEL
ALTERNATOR
RED/VIO
RD/VI
ORG/YEL
STARTER
CONTROL
RESISTANCE
BLK/YEL
RED/YEL
BLU (COM)
WHT (HOLD)
MAIN BREAKER
AUX SWITCH
GLOW PLUGS
SOLENOID
BLK
Owner’s Manual for MLT Light Tower
BLK/WHT
RED (PULL)
RED
RED/WHT
BLK/YEL
VIO/YEL
RED/YEL
N/C
N/O
12V BATTERY
TIME DELAY
RELAY
-
+
COM
RD/VI
STARTER SWITCH
GRY/VIO
GRY/BLU
OVERHEAT
WARNING
SWITCH (N.O.)
VI/YL
10 AMP
CIRCUIT
BREAKER
BLK
RED
BLK/WHT
OIL
PRESSURE
WARNING
SWITCH (N.C.)
FUEL
PUMP
VIO/YEL
VIO/YEL
HOUR
Wiring Diagrams
DC Wiring Diagram—Mitsubishi
90340_C_04.23.13
35
BLK/WHT
"TURN MAIN
BREAKER OFF"
WARNING LIGHT
RD/VI
BK
BK/WT
BK/YL
ALTERNATOR
OR/YL
RD/YL
MAIN BREAKER
AUX SWITCH
GLOW PLUGS
RD/VI
(HOLD)
VI/YL
RD/YL
BK
36
STARTER
RD
RD/WT
N/C
N/O
12V BATTERY
RD/VI
RD
RD/VI
TIME DELAY
RELAY
-
+
COM
STARTER SWITCH
BK/YL
BK
VI/YL
GY/VI
GY/BL
10 AMP
CIRCUIT
BREAKER
OVERHEAT
WARNING
SWITCH (N.O.)
YL
VI/YL
BK
RD
OIL
PRESSURE
WARNING
SWITCH (N.C.)
FUEL
PUMP
HOUR
BK/WT
SOLENOID (PULL)
Wiring Diagrams
DC Wiring Diagram—Kubota
90339_E_01.30.14
Owner’s Manual for MLT Light Tower
BK/WT
Owner’s Manual for MLT Light Tower
P1
J1
1
BN1
BN
BN
BK
2
BK1
30
87A
85
DOWN
PROX. SWITCH 1
86
DOWN
PROX. RELAY
87
BL
3
BL1
BK
VI
BK
BK
5
BN2
UP
DOWN
BN
SWITCH 1
5A
F1
WT
BK
6
BK2
30
87A
85
UP
PROX. SWITCH 2
86
UP
PROX. RELAY
87
BL
7
BL2
BK
VI/YL
GN
WINCH
BL
1
YL
BK
-
+
BATTERY
BN
RD
YL
BK
CONTACTOR 1
2
BK
BL
BK
BK
3
4
5
1
2
3
4
6
7
VIEWED FROM
WIRE INSERTION END
1
2
5
P1
VIEWED FROM
WIRE INSERTION END
6
7
J1
Wiring Diagrams
DC Wiring Diagram—Electric Winch
90443_H_06.10.14
37
-
TIME
DELAY
B
R2
BR
C
ACC
STARTER SWITCH
R1
LIGHT
FUSE
10A
ALT CONFIG
MTB PIN 12
INTERIOR LIGHT
WT/VI
+
COM
NO
NC
PNK
BK1
TO
GND
BAR
CIRCUIT
BREAKER
20A
GND
GY
PASS
OPT
2
1
OR/YL1
ESTOP
4
3
TO CNTRL
PANEL START
SOL WIRE
OR/YL2
TO MAIN
BREAKER AUX
SWITCH NC PIN
TO
GND
BAR
BK/WT2
RPM
SENSOR
BATTERY
DISCONNECT
BATTERY DISCONNECT
SOL
12 V
BATTERY
+
BK/WT
RD
GND
BK/WT1
-
FLOAT
SWITCH
SW
12 V
BATTERY
RPM
BK
RD
RD/WT
PWR
WT
PASS
SOLENOID
WT
SPLICE
BK
-
+
COM
TIME
DELAY
NO
NC
BLU
YEL/GRN
BRN
B
R2
BR
C
ACC
RD/WT
RD/VI
STARTER SWITCH
R1
86
16/3
BATTERY
CHARGER
87
RD/BK
30
87A
85
12 V
BATTERY
HEATED FUEL FILTER
EDISON PLUG
RED
BK/WT
BK
SPLICE
BATTERY CHARGER
BLK
+
POSITIVE AIR SHUTDOWN 6-20KW
RD/BK
BK/WT
TO
GND
BAR
BK
BK
SPLICE
-
+
38
-
LOW FUEL SHUTDOWN
25A
FUSE
Wiring Diagrams
DC Wiring Diagrams for Optional Equipment
90323_K_06.04.14
Owner’s Manual for MLT Light Tower
Owner’s Manual for MLT Light Tower
LEFT
TAIL/TURN
LAMP
RED
MARKER
LAMP
BK
BK
BK
BK
WT
BK
RD
WT
SPLICE
SPLICE
SPADE
SPADE
SPADE
BN
WT
SPADE
BN
LICENSE
PLATE
LAMP
WT
SPADE
AMBER
MARKER
LAMP
BK
YL
WT
BN
BN
GN
YL
BN
WT
TRAILER
PLUG
GN
RING
WT
SPLICE
SPADE
SPADE
BN
WT
BK
RD
WT
SPLICE
SPLICE
BK
BK
BK
BK
RIGHT
TAIL/TURN
LAMP
RED
MARKER
LAMP
AMBER
MARKER
LAMP
Wiring Diagrams
Trailer Lights Wiring
90341_B_12.20.13
39
Wiring Diagrams
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40
Owner’s Manual for MLT Light Tower
Wiring Diagrams
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Owner’s Manual for MLT Light Tower
41
Wiring Diagrams
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42
Owner’s Manual for MLT Light Tower
Service Log
Section 7: Service Log
OIL GRADE:______________________________________ BRAND: __________________________________
COOLANT MIXTURE: ______________________________ BRAND: __________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
Date
Hours to
Service
Oil Level
Owner’s Manual for MLT Light Tower
Coolant
Level
Date
Hours to
Service
Oil Level
Coolant
Level
43
Service Log
Notes
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44
Owner’s Manual for MLT Light Tower
Service Log
Notes
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
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Owner’s Manual for MLT Light Tower
45
Service Log
Notes
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
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46
Owner’s Manual for MLT Light Tower
Part No. 34098 Rev. C 3/8/17
©2017 Generac Mobile Products
All rights reserved.
Specifications are subject to change without notice.
No reproduction allowed in any form without prior written
consent from Generac Mobile Products.
Generac Mobile Products
215 Power Drive, Berlin, WI 54923
GeneracMobileProducts.com │800-926-9768 │920-361-4442