Generac Power Systems MLT4060MV User manual

For technical assistance contact:
www.generacmobileproducts.com
Technical Service
1-800-926-9768
SAVE THIS MANUAL FOR FUTURE REFERENCE
Owner’s Manual
Light Tower
MLT4060MV • MLT4060KV • MLT4080KV
SN ____________ and higher
004575

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 an 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.
(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.
(000393a)
WARNING
CANCER AND REPRODUCTIVE HARM
www.P65Warnings.ca.gov.

Owner’s Manual for Mobile Light Tower iii
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—MLT4060MV, MLT4060KV .......11
Control Panel—MLT4080KV .............................12
Section 3:Operation
Unit Setup ...........................................................13
Prestart Checklist ..............................................14
Raising the Mast ................................................14
Starting the Unit .................................................15
Automatic Shutdown .........................................16
Light Operation ..................................................16
Voltage Regulator (If Equipped) .......................16
Auxiliary Outlets ................................................17
Wet Stacking ......................................................17
Engine Derating .................................................17
Shutting Down the Unit .....................................17
Lowering the Mast .............................................17
Lowering the Mast—Manually ..................................18
Towing the Unit .................................................18
Lifting the Unit ...................................................19
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 .........23
Winch Mechanical Brake ...........................................23
Lower Radiator Hose Heater
(If Equipped)—Use and Maintenance ..............24
Trailer Wheel Bearings .....................................24
Jack Maintenance ..............................................24
Section 5:Troubleshooting
General Troubleshooting ..................................25
Troubleshooting the Lights ..............................26
Section 6:Wiring Diagrams
Mast Junction Box Wiring and Light
Connections .......................................................27
AC Wiring ...........................................................28
DC Wiring—Mitsubishi ......................................29
DC Wiring—Kubota ...........................................30
DC Wiring—Electric Winch ...............................31
DC Wiring for Optional Equipment ..................32
Table of Contents

iv Owner’s Manual for Mobile Light Tower
Trailer Lights Wiring ..........................................33

Owner’s Manual for Mobile Light Tower 1
Section 1: Introduction and Safety
Introduction
Thank you for purchasinga 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-
uctsproducedatthetime ofpublication.Themanufacturer
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 contact Generac Mobile at 1-800-926-
9768, or
Generac Mobile 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
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.The warnings in
this manual, and on tags and decals affixed to the unit are,
therefore, not all inclusive. If using a procedure, work
methodor operatingtechniquethatthemanufacturerdoes
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
Alwaysrecycle batteries inaccordancewithlocallawsand
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
suppliedwiththeunitwhen itwas shippedfromthefactory.
•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 guidelines 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
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.

Owner’s Manual for Mobile Light Tower 7
Section 2: General Information
Specifications
DESCRIPTION UOM MLT4060MV MLT4060KV MLT4080KV
Engine
Make (Model) — Mitsubishi®(L3E) Kubota®(D1005) Kubota®(D1105)
Type — Diesel, liquid cooled, 4-
stroke Diesel, liquid cooled, 4- stroke Diesel, liquid cooled, 4- stroke
Cylinders qty 3 3 3
Displacement in3 (L) 58.1 (0.952) 61.08 (1.00) 68.53 (1.12)
Horsepower—Prime hp (kW) 11.3 (8.4) 11.7 (8.7) 13.5 (10.1)
Horsepower—Standby hp (kW) 12.2 (9.1) 13.1 (9.8) 15.4 (11.5)
Operating Speed rpm 1800 1800 1800
Fuel Consumption—100% Load gph (Lph) 0.59 (2.23) 0.67 (2.54) TBD
EPA Certification Tier 4 Final 4 Final 4 Final
Battery—Group Number — 24 24 24
Battery—Voltage (Qty. of Batteries) VDC (qty) 12V (1) 12V (1) 12V (1)
Battery—Rating CCA 440 440 440
Capacities
Fuel Tank—Total gal (L) 57.1 (216) 57.1 (216) 56 (212)
Fuel Tank—Usable gal (L) 56.4 (213) 56.4 (213) 56 (212)
Coolant—including engine qt (L) 4.5 (4.3) 4.8 (4.5) 4.8 (4.5)
Oil—including filter qt (L) 5.0 (4.7) 5.4 (5.1) 5.4 (5.1)
Generator
Make (Model) — Marathon Electric®
(201CSA5411) Marathon Electric® (201CSA5411) Marathon Electric® (201CSA5420)
Type, Insulation — Brushless, F Brushless, F Brushless, F
Output kW (kVA) 6.0 (6.0) 6.0 (6.0) 8.0 (8.0)
Output—Voltage V 120/240, single phase 120/240, single phase 120/240, single phase
Output—Amperes 120V (240V) A 50 (25) 50 (25) 66 (33)
Frequency Hz 60 60 60
Power Factor (1Ø) — 1 1 1
Sound (23 ft at prime) dB (A) 70 70 70
AC Distribution
Circuit Breaker Size A 30 30 40
Voltage Regulation — Capacitor ±6% Capacitor ±6% Capacitor ±6%
VoltagesAvailable (1Ø) — 120, 240 120, 240 120, 240
Lighting
Lighting Type — Metal halide Metal halide Metal halide
Ballast Type — Coil & Core Coil & Core Coil & Core
Brightness lm 528,000 528,000 528,000
Trailer
Capacity—Axle Rating lb (kg) 2,200 (988) 2,200 (998) 2,200 (988)
Quantity of Axles qty 111
Tire Size in 13 13 13
Hitch—Standard size, type 2 in (51 mm), Ball 2 in (51 mm), Ball 2 in (51 mm), Ball
Maximum Tire Pressure psi 50 50 50
Unit Weight
Dry lb (kg) 1,759 (798) 1,779 (807) 1,785 (810)
Operating lb (kg) 2,162 (981) 2,182 (990) 2,188 (992)
Specifications are subject to change without notice.

8Owner’s Manual for Mobile Light Tower
General Information
Unit Dimensions
Figure 2-1. Unit Dimensions—MLT4060MV, MLT4060KV, MLT4080KV
A B C D E
115 in (2.92 m) 107 in (2.71 m) 25 ft (7.6 m) 68 in (1.73 m) 140 in (3.56 m)
A
B
C
E
D
004586

Owner’s Manual for Mobile 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.
Figure 2-2. Serial Number Locations
Unit ID Tag
Located on inside
of front panel
Serial Number
V
A
Model
KVA
Manufacturing Code
1 ph. 1.0PF 3 ph. .8PF 3 ph. 1.0PF
KW
Country of Origin
Weight (lbs/kg) RPM/Frequency
Rating
Ins. Class
FOR ELECTRICAL EQUIPMENT
ONLY.POUR MATERIAL
ELECTRIQUE SEULEMENT.
209649
Form: SFC626B
Manufactured by Generac Mobile Products LLC
[phone] [phone]
VIN Tag
TIRE AND LOADING INFORMATION
RENSEIGNEMENTS SUR LES
PNEUS ET LE CHARGEMENT
SEE OWNER’S
MANUAL FOR
ADDITIONAL
INFORMATION
VOIR LE
MANUEL DE
L’USAGER
POUR
PLUS DE
RENSEIGNEMENTS
MANUFACTURED BY/FABRIQUE PAR: Generac Mobile Products LLC DATE: 00/0000
GVWR/PNBV: 000KG (0000LBS) COLD INF. PRESS./
PRESS. DE
V.I.N./N.I.V.:
00000000000000000
TYPE: TRAILER
MODEL:
XXX000
GAWR / PNBE TIRE / PNEU RIM / JANTE GONF A FROID - KPA(PSI/LPC) SGL / DUAL
EACH
AXLE
THIS VEHICLE CONFORMS TOALL APPLICABLE STANDARDS PRESCRIBED UNDER THE U.S. FEDERAL MOTOR VEHICLE SAFETY STANDARDS(FMVSS)AND CANADIAN
MOTOR VEHICLE SAFETY REGULATIONSIN EFFECT ON THE DATE OF MANUFACTURE.
CE VEHICULE EST CONFORMEA TOUTES LES NORMES QUI LUI SONT APPLICABLES EN VERTU DU REGLEMENT SUR LASECURITE DES VEHICULES AUTOMOBILES DU CANADA EN VIGUEUR A LADATE SA
FABRICATION.
The weight of cargo should never exceed 0000KG (0000LBS)
Le poids du chargement ne doit jamais depasser 0000KG (0000LBS)
004587

10 Owner’s Manual for Mobile Light Tower
General Information
Component Locations
Figure 2-3. Component Locations
A Engine exhaust G Mast rotation knob
B Mast switch H Fuel fill (inside unit)
C Forklift pockets I Outriggers
D Battery (inside unit) J Engine access door
E Control box (inside unit) K Radiator access panel (top of unit)
F Central lift point
LEFT SIDE
RIGHT SIDE
004589
A
B
C
D
E
F
C
G
H
I
J
K

Owner’s Manual for Mobile Light Tower 11
General Information
Control Panel—MLT4060MV, MLT4060KV
Figure 2-4. Control Panel
(A) Main 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.
(B) Light Switch (4 Locations)
One circuit breaker is supplied for each light.
(C) Ballast Indicator Light (4 Locations)
Indicates power from the ballast to each light .
(D) Engine Starting Switch
Keyed switch operates glow plugs, starts and stops
engine.
(E) Glow Plug Indicator (if equipped)
Indicates operation of the engine glow plugs (Mitsubishi
engines only).
(F) Engine Hour Meter
Keeps track of engine hours for service.
(G) DC Circuit Breaker
Circuit breaker (10A) for the engine electrical system.
(H) 240V Twist-Lock Outlet
This 240V (30A) outlet supplies power for accessories
connected to the generator when the engine is running
and the main circuit breaker is switched ON (I).
(I) 120V GFCI Outlets
This 120V (20A) GFCI outlet supplies power for
accessories connected to the generator when the engine
is running and the main circuit breaker is switched ON (I).
(J) 120V Breaker
This 120V (20A) circuit breaker is supplied for the 120V
GFCI duplex outlets.
(K) Circuit Breaker Indicator Light
This light indicates that the main circuit breaker must be
opened (switched off) before starting the engine.
120V
240V
DC
BREAKER
TURN
MAIN
BREAKER
OFF
120V
BREAKER
MAIN
BREAKER
240V
BALLAST INDICATOR LIGHTS
MAST LIGHT SWITCHES
I
O
I
O
I
O
I
O
NEUTRAL BONDED TO FRAME
ON ON
ON ON ON ON
GLOW PLUG
INDICATOR
OFF
RUN
START
GLOW
PLUG
C
B
D
F
E
H
I
J
K
A
G
009003

12 Owner’s Manual for Mobile Light Tower
General Information
Control Panel - MLT4080KV
Figure 2-5. Control Panel
(A) Main Circuit Breaker
This 240V (40A) 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.
(B) Light Switch (4 Locations)
One circuit breaker is supplied for each light.
(C) Ballast Indicator Light (4 Locations)
Indicates power from the ballast to each light .
(D) 240V Breaker
This 240V (30A) circuit breaker is supplied for the 240V
twist-lock receptacle.
(E) Engine Starting Switch
Keyed switch operates glow plugs, starts and stops
engine.
(F) Glow Plug Indicator (if equipped)
Indicates operation of the engine glow plugs (Mitsubishi
engines only).
(G) Engine Hour Meter
Keeps track of engine hours for service.
(H) DC Circuit Breaker
Circuit breaker (10A) for the engine electrical system.
(I) 240V Twist-Lock Outlet
This 240V (30A) outlet supplies power for accessories
connected to the generator when the engine is running
and the main circuit breaker is switched ON (I).
(J) 120V GFCI Outlet (2 Locations)
This unit 120V (20A) GFCI outlet supplies power for
accessories connected to the generator when the engine
is running and the main circuit breaker is switched ON (I).
(K) 120V Breaker (2 Locations)
This 120V (20A) circuit breaker is supplied for the 120V
GFCI duplex outlets.
(L) Circuit Breaker Indicator Light
This light indicates that the main circuit breaker must be
opened (switched off) before starting the engine.
120V 120V
240V
DC
BREAKER
TURN
MAIN
BREAKER
OFF
120V
BREAKER
120V
BREAKER
MAIN
BREAKER
240V
BALLAST INDICATOR LIGHTS
MAST LIGHT SWITCHES
I
O
I
O
I
O
I
O
240V
BREAKER
NEUTRAL BONDED TO FRAME
I
O
ON ON
ON ON ON ON
ON ON
OFF
RUN
START
GLOW
PLUG GLOW PLUG
INDICATOR
C
B
E
G
F
I
J
K
L
A
H
009096
D

Owner’s Manual for Mobile Light Tower 13
Section 3: Operation
Unit Setup
Figure 3-1. Setup Components
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: See Unit Dimensions for mast height.
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 the 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
DETAIL C
DETAIL D
DETAIL G
DETAIL H
004591
H
J
F
A
G
ED
C
B
(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
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.

14 Owner’s Manual for Mobile Light Tower
Operation
place. Turn the jack handle clockwise to start
leveling the trailer.
7. Rotate each jack handle clockwise to start leveling
the trailer. 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
Before starting the unit, all items in the prestart check-
list must be completed. This checklist applies to both
manual and remote starting of the unit.
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.
For grounding requirements, follow the National
Electrical Code (NEC), state, and local.
Verify the Control Power switch is in the OFF (O)
position.
Verify all circuit breakers are in the OFF (O) position.
Inspect all electrical cords; repair or replace any that
are cut, worn, or bare.
Verify all winch cables are in good condition and
centered on each pulley. Do not use if cables are
kinked or beginning to unravel.
Check oil, coolant, and fuel levels. For more
information, refer to General Maintenance.
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.
Raising the Mast
1. Set up and level the unit. See Unit Setup.
Figure 3-2. Raising the Mast
(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.
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
(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.
STOP
DETAIL C
DETAIL B
A
C
B
D

Owner’s Manual for Mobile Light Tower 15
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.
3. Press and hold the winch control toggle switch (B)
upward to telescope the mast to the desired height.
Extend the mast slowly, verifying the coiled
electrical cord is extending at the top sections of
the mast.
IMPORTANT NOTE: GMASD immediately if the mast
hangs up or the winch cable develops slack.
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.
Starting the Unit
NOTE: If the engine was run out of fuel or the fuel tank
was drained, it may be necessary to bleed the fuel lines.
Refer to the engine operator’s manual supplied with the
unit.
1. See Figure 3-3. Verify the main circuit breaker and
individual circuit breakers for each of the lights are
OFF (O).
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).
Figure 3-3. Circuit Breakers in OFF (O) Position
2. See Figure 3-4. Turn the key on the Engine Start
switch to the left GLOW PLUG position and hold
the key in place for 10-15 seconds or until the glow
plug indicator turns red. (Kubota units do not have
a glow plug indicator.)
Figure 3-4. Activate Glow Plug
3. See Figure 3-5. Turn the key to the right START
position and hold it until the engine cranks and
starts running.
NOTE: For cold weather conditions, refer to the engine
operator’s manual for appropriate glow plug interval.
NOTE: If oil pressure is not obtained within 15 seconds
after the key is switched to the RUN position, the low oil
automatic shutdown will turn off the fuel supply, stopping
the engine. Check the oil level and turn the key to the
OFF position to reset the oil pressure timer before
attempting to restart the engine.
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)
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)
(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
WARNING
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)
I
O
I
O
I
O
I
O
003791
GLOW
PLUG
OFF
RUN
START
003792
CAUTION
(000230)
Equipment Damage. Do not continuously crank
engine for more than ten seconds. Doing so will lead
to overdischarge of batteries and starter seizure.

16 Owner’s Manual for Mobile Light Tower
Operation
Figure 3-5. Crank Engine
4. See Figure 3-6. Release the key, it will move to the
RUN position.
Figure 3-6. Release Key
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 (O) position to reset the unit
after the cause of shutdown has been determined.
Light Operation
1. Verify the unit is on and running smoothly.
2. See Figure 3-7. Switch the main circuit breaker (A)
ON (I).
3. Switch the individual circuit breakers for the lights
(B) to the ON (I) position, 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.
Figure 3-7. Light Switches and Breaker
NOTE: If an indicator light does not turn on, see
Troubleshooting or contact a GMASD.
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 1100W 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.
Voltage Regulator (If Equipped)
Some units may be equipped with an electronic voltage
regulator. The voltage regulator controls the output of the
generator by regulating the current into the exciter field.
The voltage regulator is adjusted before shipment from
GLOW
PLUG
OFF
RUN
START
003793
GLOW
PLUG
OFF
RUN
START
003794
(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.
400W 400W
Flagger Station Switches
120V
240V
DC
BREAKER
TURN
MAIN
BREAKER
OFF
120V
BREAKER
MAIN
BREAKER
240V
BALLAST INDICATOR LIGHTS
MAST LIGHT SWITCHES
I
O
I
O
I
O
I
O
NEUTRAL BONDED TO FRAME
ON ON
ON ON ON ON
GLOW PLUG
INDICATOR
OFF
RUN
START
GLOW
PLUG
AB C
(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.