Generac MLT4080 Generator Set

1. Apply automotive grease to internal gearing via jack cover or grease fitting near crank (side-wind models)
2. Rotate jack handle to distribute grease evenly
3. Apply lightweight oil to handle unit at both sides of tube (side-wind models)
4. Lubricate caster wheel axle bolt/nut assembly with lightweight oil if equipped
5. Apply lightweight oil to screw stem (top-wind models)

Tools: Grease gun

1. Remove small rubber plug on grease cap
2. Attach standard grease gun fitting to grease zerk fitting
3. Pump grease until new grease is visible around gun nozzle
4. Wipe excess grease from hub with clean cloth
5. Replace rubber plug

⚠ Replace cable immediately if damaged

⚠ Replace brake if slippage detected

1. Check winch is free of dirt, oil, grease, water, and foreign substances
2. Ensure all mounting bolts tightened to recommended torque values
3. Check connections are securely tightened and free of corrosion
4. Inspect cable for damage: cuts, knots, crushed or frayed portions, broken strands
5. Check brake for slippage or drift by visual inspection when winch is under load

⚠ Do not extend mast beyond the colored mark on the second mast section

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

1. Set up and level the unit
2. Check both sets of mast cables for wear or damage; verify centered in pulleys
3. Press and hold winch control toggle switch upward to telescope mast to desired height
4. Rotate mast by loosening rotation knob, aim lights, then tighten knob

1. Remove all loads from the outlets
2. Switch individual circuit breakers for each light OFF (O)
3. Switch the main circuit breaker OFF (O)
4. Move the control power switch to STOP

⚠ Do not continuously crank engine for more than ten seconds

⚠ Never start the engine with circuit breakers switched on

1. Verify main circuit breaker and individual light breakers are OFF (O)
2. Turn key to GLOW PLUG position, hold 10-15 seconds until glow plug indicator turns red
3. Turn key to START position, hold until engine cranks and starts
4. Release key; it moves to RUN position
5. Allow engine to reach normal operating temperature before switching on loads

⚠ Maximum highway towing speed 55 mph (88.5 km/h); off-road 10 mph (16 km/h) or less

Tools: grease gun

1. Raise rear jack and release locking pin into travel position
2. Raise outrigger jacks and slide outriggers into frame until locking pins snap
3. Use tongue jack to raise/lower trailer onto hitch; lock coupling and attach safety chains
4. Lubricate grease fittings on leveling jacks
5. Connect trailer wiring to tow vehicle and check lights
6. Check wheel lugs; tighten in sequence to specification if removed
7. Check tire inflation

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

Tools: 3/8 in. hex-wrench

1. Remove power cables from the two terminals on the winch motor assembly
2. Remove two flange head screws securing winch motor assembly, retain for reassembly
3. Carefully remove the motor assembly, keeping the two pieces together
4. Insert a 3/8 in. hex-wrench into the sleeve bearing
5. Rotate the wrench counter-clockwise to lower the mast, stopping if slack develops
6. Install the winch motor assembly and secure with screws once mast is fully down