Generac Power Systems MLT4060K Operating Manual Download Page 33 | Manualshive

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Maintenance

30

MLT4060-80M/K Operating Manual

10454 O

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.

3. Referring to the “Cable In/Cable Out” decal on the winch, turn handle according to the specified direction to

lift. The ratchet

MUST

make a loud clicking sound while pulling line in.

Let Line/Load Out:

1. Referring to the “Cable In/Cable Out” decal on the winch, turn handle according to the specified direction to

lower. No clicking will be heard because the brake system is activated.

Maintenance

The following procedures should be performed at least annually:

1. The gears and bushings of the winch must be kept lubricated. Apply a thin film of grease to the gear teeth,

and oil the bushings as needed.

2. The ratchet pawl pivot point must be kept lubricated with a thin oil.

3. Do not get oil or grease on the friction discs.

Figure 18 - Locations for Oil or Grease on Winch

WINCH USE, OPERATION & MAINTENANCE - ELECTRIC

•

Keep the winch free of dirt, oil, grease, water and other substances.

•

Check all mounting bolts and make sure they are tightened to the recommended torque values. Replace
any damaged fasteners.

•

Periodically check all connections to be sure they are tight and free of corrosion.

•

Check the cable for visible damage every time the winch is operated. Examples of damage are: cuts, knots,
mashed or frayed portions, and broken strands. Replace cable immediately if damaged. Failure to replace
a damaged cable could result in breakage.

•

Regularly check the brake for slippage or drift. This is detected visually when winch is under load. If winch
drum continues to turn after controls are released, the brake may need to be replaced.

00244

Oil

Grease

Friction Discs

(No Grease/Oil)

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Summary of Contents for MLT4060K

Page 1: ...OPERATING MANUAL 10454 O 09 15 01447 LIGHT TOWER MLT4060M MLT4060K MLT4080M MLT4080K www discount equipment com D i s c o u n t E q u i p m e n t c o m ...

Page 2: ...nie Terex JLG MultiQuip Mayco Toro Stone Diamond Products Magnum Airman Mustang Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Brothers Essick Miller Spreader Skyjack Lull Skytrak Tsurumi Husquvarna Target Whiteman Concrete Mortar Stow Concrete Mortar Baldor Wacker Sakai Snorkel Upright Mi T M Sullair Neal Basic Dynapac MBW Weber Bartell Bennar Newman Haulotte Ditch Runner Blaw Kno...

Page 3: ...nown 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 D i s c o u n t E q u i p m e n t c o m ...

Page 4: ... operation and maintenance procedures for the engine DO NOT MODIFY or use this equipment for any application other than for which it was designed Generac Mobile Products recommends that a trained and licensed professional perform all electrical wiring and testing functions Any wiring should be in compliance with the National Electrical Code NEC and follow local state and Occupational Safety and He...

Page 5: ...ltage Regulator Option 21 Customer Convenience Receptacles 21 Shutting Down the Unit 21 Automatic Shutdown 22 Lowering the Mast Manual 22 Lowering the Mast Electric Winch Option 22 Electronically Lowering the Mast 22 Manually Lowering the Mast 23 Removing the Lights for Transportation 24 Towing the Unit 24 Lifting the Unit 25 Section 4 Maintenance Daily Walk Around Inspection 27 General Maintenanc...

Page 6: ...ing Diagrams Mast Light Connections 35 AC Wiring 36 DC Wiring Mitsubishi Engine 37 DC Wiring Kubota Engine 38 DC Wiring Options 39 DC Wiring Option Electric Winch 40 Trailer Lights Wiring 41 Section 7 Options Accessories Lower Radiator Hose Heater Option Use and Maintenance 43 D i s c o u n t E q u i p m e n t c o m ...

Page 7: ...is equipment was designed for specific applications DO NOT modify or use this equipment for any application other than which it was designed for Equipment operated improperly or by untrained personnel can be dangerous Read the operating instructions and familiarize yourself with the location and proper use of all instruments andcontrols Inexperiencedoperatorsshouldreceiveinstructionfromsomeonefami...

Page 8: ...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 warnings described in the engine operator s manual A copy of this manual was supplied with the unit when it was shipped from the factory DO NOT run engine indoors or in an area with poor ventilatio...

Page 9: ...tbeingoodconditionandsecurelyfastened 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 Check that the hitch and coupling on the towing vehicle are rated equal to or greater than the trailer s Gross Vehicle Weight R...

Page 10: ... 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 Products LLC To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www safercar gov or write to Administrator NHTSA 1200 New ...

Page 11: ...ot surface s nearby Fire explosion hazard keep open flames away from unit Read and understand the supplied operator s manual before operating unit Ultraviolet radiation hazard operate only with lens intact Use clean diesel fuel only Unit electrical ground Anchor tie down point Lift here only Asphyxiation hazard operate in well ventilated area Dangerous voltage may be present Crush hazard keep body...

Page 12: ... kVA 6 0 6 0 6 0 6 0 Output Voltage V 120 240 single phase 120 240 single phase Output Amperes 120V 240V A 50 25 50 25 Frequency Hz 60 60 Power Factor 1 1Ø 1 1Ø Weights Dry Weight lbs kg 1675 760 1695 770 Operating Weight lbs kg 1888 856 1908 866 Capacities Fuel Tank Volume gal L 30 114 30 114 Usable Fuel Volume gal L 30 114 30 114 Coolant incl engine qt L 4 5 4 3 4 8 4 5 Oil incl filter qt L 3 8 ...

Page 13: ...0 8 0 Output Voltage V 120 240 single phase 120 240 single phase Output Amperes 120V 240V A 61 30 66 33 Frequency Hz 60 60 Power Factor 1 1Ø 1 1Ø Weights Dry Weight lbs kg 1695 769 1712 777 Operating Weight lbs kg 1908 865 1925 874 Capacities Fuel Tank Volume gal L 30 114 30 114 Usable Fuel Volume gal L 30 114 30 114 Coolant incl engine qt L 4 5 4 3 4 8 4 5 Oil incl filter qt L 3 8 3 6 5 4 5 1 Max...

Page 14: ...anual 9 Unit Dimensions Figure 1 Unit Dimensions Specifications are subject to change without notice A B C D E MLT4060M K MLT4080M K 170 in 4 32 m 70 in 1 78 m 30 ft 9 14 m 63 in 1 73 m 140 in 3 56 m D B A 00208 E C D i s c o u n t E q u i p m e n t c o m ...

Page 15: ...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 TO ALL APPLICABLE STANDARDS PRESCRIBED UNDER THE U S FEDERAL MOTOR VEHICLE SAFETY STANDARDS FMVSS AND CANADIAN MOTOR VEHICLE SAFETY REGULATIONS IN EFFECT ON THE DATE OF MANUFACTURE CE VEHICULE EST CONFORME A TOUTES LES NORMES QUI LUI SONT ...

Page 16: ...NS 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 Engine access LEFT SIDE RIGHT SIDE 10 8 9 7 1 2 4 3 6 5 01983 D i s c o u n t E q u i p m e n t c o m ...

Page 17: ...ator lights 4 9 240V twist lock receptacle 4 Control Power switch 10 120V breaker 5 Glow plug indicator 11 Circuit breaker indicator light 6 Engine hour meter 9 8 10 11 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 4 6 7 5 1 ...

Page 18: ...les 2 4 240V breaker 10 240V twist lock receptacle 5 Control Power switch 11 120V breaker 6 Glow plug indicator 12 Circuit breaker indicator light 1 2 3 5 7 8 10 4 9 12 11 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 GLOW PLUG ...

Page 19: ...oving A This will make it easier to level the unit 3 Pull the locking pin on the tongue jack and rotate the jack 90 Replace the locking pin B Turn the jack handle clockwise to raise the trailer tongue off of the towing vehicle 4 A grounding stud is located on the frame of the trailer at the base of the mast post C For grounding requirements follow any local state or National Electrical Code NEC gu...

Page 20: ...up to date For more information refer to General Maintenance on page 27 and Basic Maintenance Schedules beginning on page 28 The unit must be level The unit must be dry Check for any water inside on or near the unit dry if needed For grounding requirements follow any local state or National Electrical Code NEC guidelines Verify the Control Power switch is in the OFF O position Verify all circuit b...

Page 21: ...al position 5 Remove the safety pin from the mast lock bar C Using the handle for the lower mast winch D raise the mast until it is vertical and the tab on the mast is positioned into the mast lock The mast lock bar should snap into place automati cally Secure the lock with the safety pin E Figure 7 Raising the Mast Manual Winch 6 After the mast is up and locked into place use the upper mast winch...

Page 22: ... contact with the mastorframemayenergizethe unit and cause electrocution Repair or replace a damaged cord 4 Make sure the area around the unit is clear before raising the mast to the vertical position Figure 8 Raising the Mast Electric Winch 5 Remove the safety pin from the mast lock bar C Press the lower winch control switch D upward to raise the mast into the vertical position Hold the switch un...

Page 23: ...key on the Control Power switch to the left Glow Plug position and hold the key in place for five seconds or until the glow plug indicator turns red Kubota units do not have a glow plug indicator As soon as it is glowing turn the key to the right Start position and hold it until the engine cranks and starts running Release the key it will move to the Run position Figure 9 Circuit Breakers Note For...

Page 24: ...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 CAUTION Bulbs become extremely hot when in use Allow bulb fixture to cool 10 15 minutes before handling or lowering the mast DERATING FOR ALTITUDE All units are subject to derating for altitude and temp...

Page 25: ...e bulbs to cool before turning them back on Figure 12 Receptacle Locations With all of the lights off the full generator output may be used with the optional 240V twist lock receptacle SHUTTING DOWN THE UNIT Prior to shutting down the unit check with personnel using power supplied by the unit and let them know the power is going to be turned off Make sure the power shut down will not create any ha...

Page 26: ... by the mast while it is being lowered CAUTION STOP IMMEDIATELY if the mast hangs up or the winch cable begins to develop slack Excess slack in the cable could cause the mast to collapse which could result in personal injury or equipment damage Contact an authorized service center 4 Release the mast lock by pulling the safety pin on the mast lock and pulling the lock bar free Turn the han dle of t...

Page 27: ... to relieve pressure on the mast bar 5 After the mast is completely down insert the mast cradle locking pin and secure it with the safety pin Note If the generator is not operational and the batteries do not have enough power to lower the mast it may be necessary to lower the mast manually Manually Lowering the Mast Do not use this procedure unless it is absolutely necessary Continuous use of this...

Page 28: ...ocking pins to rotate them up into the travel position Make sure the locking pins snap into place Release the outrigger locking pins and slide the outriggers into the trailer frame until the locking pins snap into place 3 Use the tongue jack to raise or lower the trailer onto the hitch of the towing vehicle Lock the hitch coupling and attach the safety chains or cables to the vehicle Remove the to...

Page 29: ...cated on the top of the unit The central lift point is connected to a lift structure inside the unit Attach a sling or hook directly to the central lift point only if the devices are in good condition and the equip ment being used to raise the unit has sufficient capacity For approximate weights refer to Specifications begin ning on page 7 Make sure the cradle locking pin is in place Alwaysremaina...

Page 30: ...listed below Verify the Control Power switch is turned to the OFF O position Verify the circuit breakers are turned to the OFF O position Disconnect the negative terminal on the battery Attach a Do Not Start sign to the control panel This will notify everyone that the unit is being serviced and will reduce the chance of someone inadvertently trying to start the unit Never wash the unit with a high...

Page 31: ...quipment damage or premature equipment failure Maintenance records may be required to complete a warranty request Use the schedule in the following table as a guide for regular maintenance intervals For additional or replacement copies of the engine operator s manual contact an authorized dealer in your area Perform after the initial 50 hours of operation then on the regularly scheduled interval i...

Page 32: ...ace the air cleaner element yearly or after six cleanings whichever occurs first WINCH USE OPERATION MAINTENANCE MANUAL Prior to Use Inspect rope or cable and replace if damaged Check mounting hardware for proper tightness and re torque if necessary Gears ratchet pivot point and shaft bushings must be kept lubricated with a thin film of oil or grease Item Daily 50 Hours 100 Hours 200 Hours 400 Hou...

Page 33: ...ubricated Apply a thin film of grease to the gear teeth and oil the bushings as needed 2 The ratchet pawl pivot point must be kept lubricated with a thin oil 3 Do not get oil or grease on the friction discs Figure 18 Locations for Oil or Grease on Winch WINCH USE OPERATION MAINTENANCE ELECTRIC Keep the winch free of dirt oil grease water and other substances Check all mounting bolts and make sure ...

Page 34: ...failure of the brake Replace any damaged brake components before resuming use of the winch JACK MAINTENANCE The following procedures should be performed at least annually Side Wind Models The internal gearing and bushings of the jack must be kept lubricated Apply a small amount of automotive grease to the internal gearing by removing the jack cover or if equipped use a needle nose applicator or st...

Page 35: ...ch a standard grease gun fitting to the grease zerk fitting and pump grease into the fitting until new grease is visible around the nozzle of the grease gun Use only a high quality grease made specifically for lubrication of wheel bearings Wipe any excess grease from the hub with a clean cloth and replace the rubber plug when finished The minimum recommended lubrication is every 12 months or 12 00...

Page 36: ...wn Low coolant level Blockage in radiator Leakage in coolant hoses engine block or water pump Add coolant if needed Allow engine to cool then check coolant level in radiator Restart engine and check coolant temperature on controller Stop engine immediately if coolant temperature is 210 F 99 C or more Check radiator shroud and ducting for blockage and remove any foreign matter Inspect for visible l...

Page 37: ...ze at 240 260VAC On quick disconnect models measure across junction box termi nals when the light is unplugged On hard wired models remove mast junction box cover and insert wire probes into connector blocks for light and ground If proper voltage is not achieved perform capacitor check to determine if the capacitor or coil needs to be replaced Mast Lights On but the Light Output is Low Dirty fixtu...

Page 38: ... MLT4060 80M K Operating Manual 35 Section 6 Wiring Diagrams MAST LIGHT CONNECTIONS 1 3 2 4 2 1 4 3 MAST JUNCTION BOX WIRING 4 LIGHT MAST LIGHT CONNECTIONS 4 LIGHT 00175 D i s c o u n t E q u i p m e n t c o m ...

Page 39: ... 8KW UNITS ONLY 1 GN WT 3 GN WT BK 2 GN WT BK 4 GN WT BK BK 20A 30A RD RD BK BK BK BK WT GN RD YL RD BK BL WT YL RD BK BL BK RD GY RD RD RD RD RD RD GY GY BK BK BL BL BK RD YL RD BK BK RD RD BK RD BK CAP 2 CAP 1 CAP 3 CAP 4 TRANSFORMER 1 TRANSFORMER 2 TRANSFORMER 3 TRANSFORMER 4 GN GN WT WT 20A RD RD BK BK BK BK BL BK RD YL BK RD YL BK RD YL WT WT WT WT WT WT 15 A 15 A 15 A 15 A BK BK RD RD GY BL ...

Page 40: ...HT BLK WHT RED BLK FUEL PUMP 10 AMP CIRCUIT BREAKER OIL PRESSURE WARNING SWITCH N C SWITCH N O WARNING OVERHEAT 12V BATTERY STARTER RELAY TIME DELAY GRY BLU GRY VIO VI YL RED BLK CONTROL RESISTANCE BLK YEL GLOW PLUGS AUX SWITCH MAIN BREAKER RD VI ALTERNATOR WARNING LIGHT TURN MAIN BREAKER OFF BLK WHT BLK RED YEL ORG YEL RD VI RED VIO N C N O COM 90340_C_04 23 13 D i s c o u n t E q u i p m e n t c...

Page 41: ...WT RD BK FUEL PUMP 10 AMP CIRCUIT BREAKER OIL PRESSURE WARNING SWITCH N C SWITCH N O WARNING OVERHEAT 12V BATTERY STARTER RELAY TIME DELAY GY BL GY VI RD RD BK BK YL GLOW PLUGS AUX SWITCH MAIN BREAKER RD VI ALTERNATOR WARNING LIGHT TURN MAIN BREAKER OFF BK WT BK RD YL OR YL RD VI RD VI N C N O COM RD VI YL BK 90339_E_01 30 14 D i s c o u n t E q u i p m e n t c o m ...

Page 42: ...GND BAR 25A RD BK 10A MTB PIN 12 ALT CONFIG POSITIVE AIR SHUTDOWN 6 20KW BK WT RPM SENSOR PASS GND PWR RPM SW OPT GND SOL CIRCUIT BREAKER 20A BATTERY 12 V ESTOP SOLENOID PASS RD WT BK SPLICE SPLICE RD RD WT BK WT1 PNK BK1 BK BK WT BK WT2 GY TO GND BAR TO GND BAR OR YL1 OR YL2 TO CNTRL PANEL START SOL WIRE TO MAIN BREAKER AUX SWITCH NC PIN TIME DELAY NC COM NO BK SPLICE TIME DELAY NC COM NO BK WT W...

Page 43: ...INCH 2 PROX AUX RELAY 2 BLK BLK YL BL WHT BLK BRN BRN BLU BLK VI DOWN UP 12 V BATTERY RED BLK RED BLK CONTACTOR 2 SWITCH 2 SWITCH 1 BL YL RD BK BK BN GN BL YL BK RD BK BN GN 6 7 5 3 2 1 J1 P1 PROX SWITCH 2 PROX SWITCH 1 J2 P2 5A F1 5A F2 7 2 5 4 6 3 1 J VIEWED FROM WIRE INSERTION END 2 7 5 4 1 3 6 P VIEWED FROM WIRE INSERTION END CONTACTOR 1 CONTACTOR 2 90463_B_07 16 14 D i s c o u n t E q u i p m...

Page 44: ...T TAIL TURN LAMP LAMP PLATE LICENSE MARKER LAMP RED BK BK BK BK RD WT BK SPLICE SPLICE SPADE SPADE LAMP TAIL TURN LEFT RD WT BK SPADE YL BN WT SPADE SPADE WT BK BN WT SPLICE GN RING MARKER LAMP AMBER MARKER LAMP RED BK BK BK BK SPLICE SPLICE SPADE SPADE BN WT WT WT BN BN 90341_B_12 20 13 D i s c o u n t E q u i p m e n t c o m ...

Page 45: ...r mixture of water and engine coolant before each heater use The heater is designed for all night operation however 2 5 hours of heating just prior to starting is usually sufficient for proper engine starting The unit must be level to maintain proper orientation of the heater while it is in operation Use only an undamaged outdoor rated three prong grounded 120VAC extension cord with a minimum ampe...

Page 46: ...nie Terex JLG MultiQuip Mayco Toro Stone Diamond Products Magnum Airman Mustang Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Brothers Essick Miller Spreader Skyjack Lull Skytrak Tsurumi Husquvarna Target Whiteman Concrete Mortar Stow Concrete Mortar Baldor Wacker Sakai Snorkel Upright Mi T M Sullair Neal Basic Dynapac MBW Weber Bartell Bennar Newman Haulotte Ditch Runner Blaw Kno...

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