Generac MLT Light Tower Generator Set

⚠ High Voltage. Verify area above unit is clear of overhead wires and obstructions.

⚠ Do not set up if high winds expected.

Tools: jack handles

1. Position unit at ground level or higher than area to be illuminated.
2. Place unit on firm ground less than 5° slope; block wheels.
3. Pull locking pin on tongue jack, rotate 90°, install pin. Rotate handle clockwise to raise tongue off vehicle.
4. Grounding stud on frame near tongue; follow NEC, state, local regulations.
5. Pull outrigger locking pins, pull outriggers out until spring-loaded pins snap.
6. Pull locking pin on each outrigger jack, rotate 90° so jack pad faces down.
7. Pull rear jack locking pin, rotate 90° until pin snaps.
8. Turn jack handles clockwise to level trailer.
9. Adjust all four jacks until firmly in contact with ground.
10. Adjust lamps by loosening wing nuts on trunnion; aim lamps; tighten hardware.
11. Verify lamps are connected to junction box.

⚠ Water may enter cabinet and collect in generator windings, causing damage.

1. Clean Light Tower after each use to remove dust, grease, mud, spilled fuel or oil.
2. Use soft, clean rags to wipe cabinet exterior and control panel.
3. Low-pressure compressed air (less than 40 PSI [276 kPa]) can remove dust from cabinet interior.
4. Do not wash with high pressure hose or power washer.
5. Do not wash engine block or fuel tank with power washer or steam cleaner.

1. If stored outside, check for water inside cabinet and generator before each use; dry if wet.
2. Inspect electrical cords; do not use if insulation cut or worn.
3. Verify winch cables in good condition and centered on each pulley; do not use kinked or unraveling cable.
4. Verify mast cable correct.
5. Verify safety pins for mast lock rod and mast lock bar present and secured with chain; check spring in mast lock bar.
6. Verify wheel lugs present and properly tightened.
7. Check coolant level daily in overflow jug; normal level between full and add.
8. Check oil level daily; do not start if below add mark; add only if below add mark; do not overfill.
9. Check fuel level.

Tools: grease gun, needle nose applicator

1. For side-wind models, keep internal gearing and bushings lubricated.
2. Apply small amount of automotive grease to internal gearing by removing jack cover or use needle nose applicator/grease gun on lubrication point.
3. Rotate jack handle to distribute grease evenly.
4. Apply lightweight oil to handle unit at both sides of tube for side-wind models.
5. If equipped, lubricate axle bolt and nut assembly of caster wheel with same lightweight oil.
6. For top-wind models, apply lightweight oil to screw stem.

⚠ Continuous use of this procedure could damage planetary gear brake of winch.

Tools: 3/8" allen head wrench

1. Remove power cables from two terminals on winch motor assembly.
2. Remove two flange head screws securing winch motor assembly to winch; retain screws.
3. Carefully remove motor assembly; ensure two pieces do not separate.
4. Insert 3/8" allen head wrench into sleeve bearing.
5. Rotate wrench counterclockwise to lower mast. If slack observed in cable, stop immediately and remove slack.
6. When mast completely down, install winch motor assembly and secure with screws.

⚠ DO NOT perform routine service unless all electrical components are shut down.

1. Verify key switch is OFF.
2. Verify circuit breakers switched OFF (O).
3. Disconnect negative (–) terminal on battery.
4. Attach "Do Not Start" sign to control panel.

Tools: grease gun

1. Remove small rubber plug on grease cap.
2. Attach standard grease gun fitting to grease zerk fitting.
3. Pump grease into fitting until new grease visible around nozzle.
4. Use only high quality grease for wheel bearings.
5. Wipe excess grease from hub and replace rubber plug.

⚠ Failure to replace damaged cable could result in breakage.

⚠ Overheating mechanical brake may cause permanent damage.

1. Keep winch free of dirt, oil, grease, water and other substances.
2. Check all mounting bolts and tighten to recommended torque values; replace damaged fasteners.
3. Periodically check all connections tight and free of corrosion.
4. Check cable for visible damage every time winch is operated; replace damaged cable immediately.
5. Regularly check brake for slippage or drift; if drum continues to turn after controls released, brake may need replacement.
6. Periodically clean and grease brake assembly.
7. Check motor brushes periodically and replace when necessary.

⚠ Make sure mast winch handles or other obstructions are clear of forklift tines before lifting.

1. Verify lifting equipment in good condition and sufficient capacity.
2. Close and lock all hoods and doors; stow lights.
3. Verify cradle locking pin in place.
4. Attach slings, chains, or hooks directly to central lifting eye.
5. Remain aware of people and objects around unit.
6. Use upper or lower forklift pockets with care; approach perpendicular.

⚠ Allow 10–15 minutes for lamps to cool before handling or lowering mast.

⚠ Stop immediately if mast hangs up or winch cable develops slack.

1. Shut down lights and engine.
2. If moving trailer, rotate mast so lights face back: loosen mast rotation knob, rotate until white arrows aligned and metal stop tabs touching, tighten knob.
3. Press and hold winch control toggle switch downward to collapse mast.
4. Verify electrical cord does not get caught or pinched.
5. Use manual lowering procedure if generator not operational and batteries lack power.

⚠ Do not extend mast beyond colored mark.

⚠ Stop immediately if mast hangs up or winch cable develops slack.

1. Set up and level unit.
2. Check both sets of mast cables for wear/damage; verify cables centered in each pulley; check electrical cord.
3. Press and hold winch control toggle switch upward to telescope mast to desired height.
4. Extend mast slowly; verify coiled electrical cord extends at top sections.
5. Do not extend past colored mark.
6. To rotate mast, loosen mast rotation knob, turn mast until lights face desired direction, tighten knob.

1. Remove all loads from outlets.
2. Switch individual circuit breakers for each light OFF (O).
3. Switch main circuit breaker OFF (O).
4. Turn engine start switch to STOP.
5. For extended storage, disconnect battery.