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Table of Contents
Troubleshooting
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Summary of Contents for Generac Power Systems MLT4060M
- Page 1 LIGHT TOWER MLT4060M • MLT4060K MLT4080M • MLT4080K OPERATING MANUAL 01447 www.discount-equipment.com 10454 O 09/15...
- Page 2 Discount-Equipment.com is your online resource for commercial and industrial quality parts and equipment sales. Locations: Florida (West Palm Beach): 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Check out our website at www.discount-equipment.com Can’t find what you need? Click on this link: http://www.discount-equipment.com/category/5443-parts/ and fill out the request form.
- Page 3 WARNING 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.
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Page 4: Introduction
Introduction 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. -
Page 5: Table Of Contents
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.......................... - Page 6 General Troubleshooting Guide ..................33 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..........................
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Page 7: Section 1 - Safety
Section 1 - Safety SAFETY NOTES 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. -
Page 8: Engine Safety
Safety • 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. -
Page 9: Service Safety
Safety • Keep area around exhaust pipes and air ducts free of debris to reduce the chance of an accidental fire. 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. -
Page 10: Reporting Trailer Safety Defects
Safety 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. -
Page 11: Safety Symbol Summary
Safety 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. -
Page 12: Section 2 - General Information
Section 2 - General Information 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... - Page 13 General Information 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 (L) ..............57.97 (0.95) ......68.53 (1.12)
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Page 14: Unit Dimensions
General Information Unit Dimensions 00208 Figure 1 - Unit Dimensions MLT4060M/K, 170 in 70 in 30 ft 63 in 140 in MLT4080M/K (4.32 m) (1.78 m) (9.14 m) (1.73 m) (3.56 m) Specifications are subject to change without notice. 10454 O... -
Page 15: Unit Serial Number Locations
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. -
Page 16: Component Locations
General Information COMPONENT LOCATIONS 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. -
Page 17: Control Panel - Mlt4060M, Mlt4060K
START 120V 240V BREAKER NEUTRAL BONDED TO FRAME 00165 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. -
Page 18: Control Panel - Mlt4080M, Mlt4080K
General Information CONTROL PANEL - MLT4080M, MLT4080K BALLAST INDICATOR LIGHTS MAIN BREAKER 240V TURN MAIN BREAKER MAST LIGHT SWITCHES 120V 120V BREAKER BREAKER GLOW PLUG GLOW INDICATOR PLUG 240V START BREAKER 120V 120V 240V BREAKER NEUTRAL BONDED TO FRAME 00162 Figure 5 - Control Panel Component Locations (MLT4080M, MLT4080K) 1. -
Page 19: Section 3 - Operation
Section 3 - Operation 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. -
Page 20: Prestart Checklist
Operation 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. -
Page 21: Raising The Mast
Operation RAISING THE MAST 1. Set up and level the unit. Refer to “Light Tower Set Up” on page WARNING The unit must be leveled with the outriggers extended before raising the mast. The DETAIL A DETAIL C DETAIL E outriggers must remain extended while the mast is up. -
Page 22: Raising The Mast With Electric Winch Option
Operation 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. -
Page 23: Starting The Unit
Operation 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. 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. -
Page 24: Light Operation
Operation 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. -
Page 25: Voltage Regulator Option
Operation 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. -
Page 26: Automatic Shutdown
Operation 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. -
Page 27: Manually Lowering The Mast
Operation 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. -
Page 28: Removing The Lights For Transportation
Operation 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. -
Page 29: Lifting The Unit
Operation 10. 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. Start all lug nuts by hand. b. -
Page 30: Section 4 - Maintenance
Section 4 - Maintenance 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. -
Page 31: Basic Maintenance Schedule - Mitsubishi Engine
Maintenance 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. ○... -
Page 32: Basic Maintenance Schedule - Kubota Engine
Maintenance 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. -
Page 33: Operation
Maintenance 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. -
Page 34: Winch Preventive Maintenance Schedule
Maintenance • 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. •... -
Page 35: Top-Wind Models
Maintenance Top-Wind Models • Apply a lightweight oil to the screw stem. Grease Grease Grease 00243 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. -
Page 36: Section 5 - 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 engine operator’s manual for additional troubleshooting information or contact Generac Mobile Products Technical Service at 1-800-926-9768. -
Page 37: Troubleshooting The Lights
Troubleshooting TROUBLESHOOTING THE LIGHTS Table 2 - Troubleshooting the Lights Guide Possible Cause Solution Problem Mast Lights Off but Bal- Mast light too hot Allow light to cool 10-15 minutes before restarting. last Indicators on Con- trol Panel are On Faulty bulb connection Check bulb is tight in socket. -
Page 38: Section 6 - Wiring Diagrams
Section 6 - Wiring Diagrams MAST LIGHT CONNECTIONS MAST JUNCTION BOX WIRING MAST LIGHT CONNECTIONS 4-LIGHT 4-LIGHT 00175 10454 O MLT4060-80M/K Operating Manual... -
Page 39: Ac Wiring
Wiring Diagrams AC WIRING 90347_E_06.21.14 MLT4060-80M/K Operating Manual 10454 O... -
Page 40: Dc Wiring - Mitsubishi Engine
Wiring Diagrams DC WIRING - MITSUBISHI ENGINE 10454 O MLT4060-80M/K Operating Manual... -
Page 41: Dc Wiring - Kubota Engine
Wiring Diagrams DC WIRING - KUBOTA ENGINE 90339_E_01.30.14 MLT4060-80M/K Operating Manual 10454 O... -
Page 42: Dc Wiring Options
Wiring Diagrams DC WIRING OPTIONS 90323_K_06.04.14 10454 O MLT4060-80M/K Operating Manual... -
Page 43: Dc Wiring Option - Electric Winch
Wiring Diagrams DC WIRING OPTION - ELECTRIC WINCH 90463_B_07.16.14 MLT4060-80M/K Operating Manual 10454 O... -
Page 44: Trailer Lights Wiring
Wiring Diagrams TRAILER LIGHTS WIRING 90341_B_12.20.13 10454 O MLT4060-80M/K Operating Manual... -
Page 45: Section 7 - Options & Accessories
Section 7 - Options & Accessories 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. - Page 46 Discount-Equipment.com is your online resource for commercial and industrial quality parts and equipment sales. Locations: Florida (West Palm Beach): 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Check out our website at www.discount-equipment.com Can’t find what you need? Click on this link: http://www.discount-equipment.com/category/5443-parts/ and fill out the request form.