Generac Power Systems MLT3060MV User manual

Owner’s Manual

Light Tower

MLT3060MV • MLT3060KV

SN _______________ and higher

SAVE THIS MANUAL FOR FUTURE REFERENCE

For technical assistance contact:

www.generacmobileproducts.com

Technical Support

1-800-926-9768

Use this page to record important information about your light tower

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 a Generac Mobile Authorized Service

Dealer (GMASD) 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 GMASD. 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.

Unit Model No.

Unit Serial No.

Engine Model No.

Engine Serial No.

Generator Model No.

Generator Serial No.

(000393a)

WARNING

CANCER AND REPRODUCTIVE HARM

www.P65Warnings.ca.gov.

(000394)

WARNING

Breathing diesel engine exhaust exposes you

to chemicals known to the State of California

to cause cancer and birth defects or other

reproductive harm.

• Always start and operate the engine in a

well-ventilated area.

• If in an enclosed area, vent the exhaust to

the outside.

• Do not modify or tamper with the exhaust

system.

• Do not idle the engine except as necessary.

For more information go to

www.P65Warnings.ca.gov/diesel.

Owner’s Manual for Mobile Light Tower iii

Table of Contents

Section 1:Introduction and Safety

Introduction ..........................................................1

Read This Manual Thoroughly ....................................1

How to Obtain Service .................................................1

Safety Rules .........................................................1

General Hazards ..................................................2

Explosion and Fire Hazards ................................2

Trailer Hazards .....................................................2

Electrical Hazards ................................................3

Battery Hazards ...................................................3

Fuel Hazards ........................................................4

Engine Safety .......................................................4

Operating Safety ..................................................4

Positioning the Unit .....................................................4

Starting the Unit ...........................................................4

Raising and Lowering the Mast ...................................5

Service Safety ......................................................5

Towing Safety ......................................................6

Hitch and Coupling ......................................................6

Running Lights ............................................................6

Wheels and Tires ........................................................6

Safe Towing Techniques .............................................6

Reporting Trailer Safety Defects ........................6

Section 2:General Information

Specifications ......................................................7

Unit Dimensions .................................................8

Unit Serial Number Locations ............................9

Component Locations .......................................10

Control Panel .....................................................11

Section 3:Operation

Light Tower Setup .............................................13

Prestart Checklist ..............................................14

Raising the Mast ................................................14

Starting the Unit .................................................15

Automatic Shutdown .........................................15

Light Operation ..................................................16

Auxiliary Outlets ................................................16

Wet Stacking ......................................................16

Engine Derating .................................................16

Shutting Down the Unit .....................................17

Lowering the Mast .............................................17

Lowering the Mast—Manually ..................................17

Towing the Unit .................................................18

Lifting the Unit ...................................................18

Section 4:Maintenance

Emissions Information ......................................21

Daily Walk-Around Inspection .........................21

General Maintenance ........................................21

Preparing for Service .................................................21

Cleaning the Unit .......................................................21

Inspecting the Unit .....................................................21

Basic Maintenance Schedule ...........................22

Winch Use, Operation, and Maintenance ........24

Winch Mechanical Brake ...........................................24

Lower Radiator Hose Heater Use and Mainte-

nance (If Equipped) ...........................................24

Trailer Wheel Bearings .....................................24

Jack Maintenance ..............................................25

Section 5:Troubleshooting

General Troubleshooting ..................................27

Troubleshooting the Lights ..............................28

Section 6:Wiring Diagrams

Mast Junction Box Wiring and Light Connec-

tions ....................................................................29

AC Wiring ...........................................................30

DC Wiring—Mitsubishi ......................................31

DC Wiring—Kubota ...........................................32

DC Wiring—Electric Winch ...............................33

DC Wiring Diagrams—Options (If Equipped) .34

Trailer Lights ......................................................35

iv Owner’s Manual for Mobile Light Tower

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Owner’s Manual for Mobile Light Tower 1

Section 1: Introduction and Safety

Introduction

Thank you for purchasing a Generac Mobile product. This

unit has been designed to provide high performance,

efficient operation, and years of use when maintained

properly.

The information in this manual is accurate based on prod-

uctsproducedat thetimeofpublication.The manufacturer

reserves the right to make technical updates, corrections,

and product revisions at any time without notice.

Read This Manual Thoroughly

Ifanysectionofthemanualisnotunderstood,contactyour

nearest GMASD, or Generac MobileTechnical 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

thattheunitisapplied,used,andmaintainedinaccordance

withthemanufacturer'sinstructionsandrecommendations.

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

Whentheunitrequiresservicingorrepairs,contactaGMASD

for assistance. Service technicians are factory-trained and

are capable of handling all service needs. For assistance

locating a dealer, visit

www.generacmobileproducts.com/

parts-service/find-service

When contacting a GMASD

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.

Safety Rules

The manufacturer cannot anticipate every possible

circumstance that might involvea hazard. Thewarnings in

this manual, and on tags and decals affixed to the unit are,

therefore, not all inclusive. If using a procedure, work

methodoroperatingtechniquethatthe manufacturerdoes

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.

Throughoutthispublication,andontagsanddecalsaffixed

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:

NOTE: Notes contain additional information important to

a procedure and will be found within the regular text of

this manual.

These safety alerts cannot eliminatethe hazards that they

indicate. Common sense and strict compliance with the

special instructions while performing the action or service

are essential to preventing accidents.

(000100a)

WARNING

Consult Manual. Read and understand manual

completely before using product. Failure to

completely understand manual and product

could result in death or serious injury.

(000001)

DANGER

Indicates a hazardous situation which, if not avoided,

will result in death or serious injury.

(000002)

WARNING

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury.

(000003)

CAUTION

Indicates a hazardous situation which, if not avoided,

could result in minor or moderate injury.

2Owner’s Manual for Mobile Light Tower

Introduction and Safety

General Hazards Explosion and Fire Hazards

Trailer Hazards

Asphyxiation. Running engines produce

carbon monoxide, a colorless, odorless,

poisonous gas. Carbon monoxide, if not

avoided, will result in death or serious injury.

(000103)

DANGER

(000107)

WARNING

Hearing Loss. Hearing protection is

recommended when using this machine.

Failure to wear hearing protection could

result in permanant hearing loss.

(000111)

WARNING

Moving Parts. Keep clothing, hair, and

appendages away from moving parts. Failure

to do so could result in death or serious injury.

(000108)

WARNING

Hot Surfaces. When operating machine, do not

touch hot surfaces. Keep machine away from

combustibles during use. Hot surfaces could

result in severe burns or fire.

WARNING

Risk of injury. Do not operate or service this machine

if not fully alert. Fatigue can impair the ability to

service this equipment and could result in death or

serious injury. (000215)

(000139)

WARNING

Risk of burns. Allow engine to cool before

draining oil or coolant. Failure to do so could

result in death or serious injury.

(000105)

DANGER

Explosion and Fire. Fuel and vapors are

extremely flammable and explosive. Add fuel

in a well ventilated area. Keep fire and spark

away. Failure to do so will result in death

or serious injury.

(000147)

WARNING

Risk of Fire. Unit must be positioned in a

manner that prevents combustible material

accumulation underneath. Failure to do so

could result in death or serious injury.

(000110)

WARNING

Risk of Fire. Hot surfaces could ignite

combustibles, resulting in fire. Fire could

result in death or serious injury.

WARNING

Personal injury. Trailer must be securely coupled to

the hitch with the chains correctly attached. Uncoupled

or unchained towing could result in death or serious

injury. (000233a)

Personal injury. Do not operate unit during transport.

Doing so could result in death, serious injury, or

property damage.

(000231a)

WARNING

(000234a)

WARNING

Crushing hazard. Verify unit is properly secured and

on level ground. An unsecured unit can suddenly roll

or move, causing death or serious injury.

WARNING

Property or Equipment Damage. Tighten wheel lug

nuts after first 50 miles to factory specifications.

Failure to do so could result in death, serious injury,

property or equipment damage. (000235)

Owner’s Manual for Mobile Light Tower 3

Introduction and Safety

Electrical Hazards Battery Hazards

Alwaysrecyclebatteriesinaccordance withlocallawsand

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

(000145)

DANGER

Electrocution. In the event of electrical accident,

immediately shut power OFF. Use non-conductive

implements to free victim from live conductor. Apply

first aid and get medical help. Failure to do so will

result in death or serious injury.

(000104)

DANGER

Electrocution. Water contact with a power

source, if not avoided, will result in death

or serious injury.

(000144)

DANGER

Electrocution. Contact with bare wires,

terminals, and connections while generator

is running will result in death or serious injury.

(000152)

DANGER

Electrocution. Verify electrical system is

properly grounded before applying power.

Failure to do so will result in death or serious

injury.

(000188)

DANGER

Electrocution. Do not wear jewelry while

working on this equipment. Doing so will

result in death or serious injury.

DANGER

Electrocution. DO NOT use the unit if

electrical cord is cut or worn through. Doing

so will result in death or serious injury.

(000263a)

(000188)

DANGER

Electrocution. Do not wear jewelry while

working on this equipment. Doing so will

result in death or serious injury.

(000137a)

WARNING

Explosion. Batteries emit explosive gases while

charging. Keep fire and spark away. Wear protective

gear when working with batteries. Failure to do so

could result in death or serious injury.

(000162)

WARNING

Explosion. Do not dispose of batteries in a fire.

Batteries are explosive. Electrolyte solution can cause

burns and blindness. If electrolyte contacts skin or eyes,

flush with water and seek immediate medical attention.

(000163a)

WARNING

Risk of burn. Do not open or mutilate batteries.

Batteries contain electrolyte solution which can

cause burns and blindness. If electrolyte contacts

skin or eyes, flush with water and seek immediate

medical attention.

WARNING

(000228)

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.

4Owner’s Manual for Mobile Light Tower

Introduction and Safety

Fuel Hazards

•DO NOT fill fuel tank near an open flame, while

smoking, or while engine is running. DO NOT fill

tank in an enclosed area with poor ventilation.

•DO NOT operate with the fuel tank cap loose or

missing.

Engine Safety

Internal combustion engines present special hazards

during operation and fueling. Failure to follow the safety

guidelines described below could result in severe injury or

death. Read and follow all safety alerts described in the

engine operator's manual. A copy of this manual was

suppliedwiththeunitwhenit wasshippedfromthefactory.

•DO NOT run engine indoors or in an area with poor

ventilation. Make sure engine exhaust cannot seep

into closed rooms or ventilation equipment.

•DO NOT clean air filter with gasoline or other types

of low flash point solvents.

•DO NOT operate the unit without a functional

exhaust system.

•Shut the engine down if any of the following

conditions exist during operation:

• Noticeable change in engine speed.

• Loss of electrical output.

• Equipment connected to the unit overheats.

• Sparking occurs.

• Engine misfires or there is excessive engine/

generator vibration.

• Protective covers are loose or missing.

• Ambient air temperature is above 120°F (49°C).

Operating Safety

Positioning the Unit

•The area immediately surrounding the unit should

be dry, clean, and free of debris.

•Position and operate the unit on a firm, level

surface.

•If the unit is equipped with a frame grounding stud,

follow the National Electrical Code (NEC), state,

and local regulations when connecting.

Starting the Unit

(000192)

DANGER

Explosion and fire. Fuel and vapors are extremely

flammable and explosive. No leakage of fuel is

permitted. Keep fire and spark away. Failure to do

so will result in death or serious injury.

(000174)

DANGER

Risk of fire. Allow fuel spills to completely dry

before starting engine. Failure to do so will

result in death or serious injury.

(000260a)

High Voltage. Verify area above unit is clear

of overhead wires and obstructions. Contact

with high-voltage power lines will result in

death or serious injury.

DANGER

(000277)

WARNING

Burn hazard. Never operate lights with a

damaged or missing lens cover. Lamps are

hot and pressurized while in use. Unprotected

lamps can shatter, causing severe injury.

DANGER

Electrocution. DO NOT use the unit if

electrical cord is cut or worn through. Doing

so will result in death or serious injury.

(000263a)

CAUTION

(000291)

Equipment damage. Do not attempt to start or operate

a unit in need of repair or scheduled maintenance.

Doing so could result in serious injury, death, or

equipment failure or damage.

WARNING

Owner’s Manual for Mobile Light Tower 5

Introduction and Safety

Raising and Lowering the Mast

•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

GMASD.

•NEVER remove safety pin or pull mast locking pin

while tower is up.

Service Safety

This unit uses high voltage circuits capable of causing

serious injury or death. Only a qualified and licensed

electrician should troubleshoot or repair problems

occurring in this equipment.

•

Before servicing the unit, verify the Control Power

switch and circuit breakers are in the OFF (O)

position, and the negative (-) terminal on the battery

is disconnected.

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.

WARNING

Electrocution. Do not set up or operate

this unit if severe weather is expected.

Lightning strikes can kill or cause severe injury

even if you are not touching the unit. (000296)

WARNING

(000297)

> 60 mph Do not set up the unit if high winds

are expected. High winds can cause the

unit to tip or fall, causing severe injury

or machine damage.

(000279)

Personal injury or equipment damage. Do not raise

or lower the mast while the unit is operating.

Doing so can break the lenses and cause the

lamps to shatter.

WARNING

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

(000266)

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.

(000278)

WARNING

Burn hazard. Lamps become extremely hot

while in use. Allow 10–15 minutes for cooling

before handling or lowering mast. Touching a

hot lens or fixture can cause severe burns.

6Owner’s Manual for Mobile Light Tower

Introduction and Safety

Towing Safety

Towing a trailer requires care. Both the trailer and vehicle

must be in good condition and securely fastened to each

other to reduce the possibility of an accident. Some states

require that large trailers be registered and licensed.

Contact your local Department of Transportation office to

check on license requirements for your particular unit.

Hitch and Coupling

•Verify the hitch and coupling on the towing vehicle

are rated equal to, or greater than, the trailer's

Gross Vehicle Weight Rating (GVWR).

•Verify the trailer hitch and the coupling are

compatible. Make sure the coupling is securely

fastened to the vehicle.

•DO NOT tow trailer using defective parts. Inspect

the hitch and coupling for wear or damage.

•Connect safety chains in a crossing pattern under

the tongue.

•Before towing the trailer, verify that the weight of

the trailer is equal across all tires. On trailers with

adjustable height hitches, adjust the angle of the

trailer tongue to keep the trailer as level as

possible.

•Attach the breakaway cable to the rear bumper of

the towing vehicle.

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.

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.

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.

To contact NHTSA, you may either call the Auto Safety

Hotlinetoll-freeat1-888-327-4236(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.

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