INSTRUCTION SHEET. Diffused Metal Halide Kit for Vertical Mast MLTs. Overview. Models Affected. Kit Components. Recommended Tools WARNING WARNING

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1 INSTRUTION SHEET iffused Metal Halide Kit for Vertical Mast MLTs Overview These instructions illustrate installation of the iffused Metal Halide Kit. This kit is not compatible with LE lights or LE light towers. NOTE: It is necessary to enlist the help of an assistant during kit assembly. Models ffected Select 6S series MLTs Select 3000V-, 4000V-, and 5000V-series MLTs onsult Manual. Read and understand manual completely before using product. Failure to completely understand manual and product could result in death or serious injury. (000100a) Kit omponents WRNING WRNING Equipment damage. Only qualified service personnel may install, operate, and maintain this equipment. Failure to follow proper installation requirements could result in death, serious injury, and equipment or property damage. (000182a) E F G M N L K J H Item PN Qty escription Instructions OVER,OX,2 GNG,PLST NUT, HEX G8 Z WSHER,.500 SPLIT LOK Z SREW, X4.000 ST HEX G5 Z E WSHER,.500 FLT 1.060/.110 Z, G8 F SREW X.500 TRUSS PHIL 18-8 SS G One of the following: WELMENT ROP FRME LIGHT MOUNT WELMENT RKET MNT VERT MST H STRIN RLF,.75 NPT.545/.709 I, WT J WSHER,.375 FLT.810/.060 ZY HRENE K NUT, NYLK G5 Z L SREW, 6-32X.750 PN PHIL G2 Z M ERING.75 O X.5 I X.5 L X 1 FLNGE N SSY MH IFFUSE LIGHT FIXTURE MLT kits only: SREW, X3.000 ST HEX G5 Z Recommended Tools Step ladders, lift, or platform ross-blade screwdriver ombination wrenches 5/16, 7/16, 3/4, 9/16, 11/16, 1-1/8 in. lean gloves lean towel PN

2 Installation: MLT6S NOTE: See page 6 for other vertical mast MLTs. Preparing Unit for Service WRNING urn hazard. Lamps become extremely hot while in use. llow minutes for cooling before handling or lowering mast. Touching a hot lens or fixture can cause severe burns. (000278) 1. Fully retract mast. 2. Place unit on firm, flat surface. 3. lock wheels. 4. Verify unit is OFF, the engine is cool, and the lamps are cool. 5. isconnect negative (-) battery cable. Removing Standard Equipment Unless specified, parts removed in this section do not need to be retained for later installation. 1. See Figure 1. Remove lid of junction box. 8. See Figure 2. Remove light fixtures from crossbar. Figure 2. Light Fixture Removal 9. See Figure 3. Remove bulbs from light fixtures: Remove hardware (), lid (), and gasket (). Unfasten bulb support (). Remove and retain bulb. IMPORTNT NOTE: When checking or replacing the ###### Figure 1. Junction ox Lid Removal 2. isconnect all wires in junction box. 3. Loosen strain reliefs securing light cables. NOTE: o not loosen strain relief securing coil-cord until instructed. 4. Remove light cords from junction box. 5. Remove junction box from mast. 6. Loosen strain relief securing coil-cord. 7. Remove coil-cord from junction box ###### Figure 3. ulb Removal ###### PN

3 10. See Figure 4. Remove crossbar from mast. Installing Metal Halide Kit 1. See Figure 6. Install mounting weldment () to mast. Tighten hardware to 20 ft-lb (27.2 Nm) ###### Figure 4. rossbar Removal 11. See Figure 5. Remove and retain tubing clamp (). Figure 6. Mounting Weldment Installation Weldment, drop frame, light mount Washer,.375 flat.180/.060 ZY hardened Nut, NYLK G5 Z ###### 2. See Figure 7. Obtain light fixture (). Remove and retain hardware securing sides of lid. Figure 5. Tubing lamp Removal ###### ###### Figure 7. Hardware Removal Side of Lid ssembly, light fixture PN

4 3. See Figure 8. Remove and retain hardware securing top of lid. Remove and retain lid. 5. Install lid to new light fixture, as follows. IMPORTNT NOTE: Excessive torque can strip screw heads and damage threads. See Figure 8. Install lid using hardware retained in step 3, lubricating surfaces of rubber washers before installing. Tighten hardware to 19.7 ft-lb (26.7 Nm). See Figure 7. Install hardware retained in step 2. Tighten to 75 in-lb (8.5 Nm). 6. See Figure 10. Install bearings () to light fixture. rrange light fixture so strain relief () faces away from mast Figure 8. Lid Removal IMPORTNT NOTE: When checking or replacing the 4. See Figure 9. Install bulbs, as follows. Pinch at () to release spring-clamp brace. Pivot as illustrated (). Install bulb (). Secure bulb with spring-clamp brace as shown (). Figure 10. earing Installation; Proper Light Position earing.75 O X.5 I X.5 L X 1 [part of light fixture] See Figure 11. Install light fixture to mounting weldment. Tighten hardware to 43 ft-lb (58.3 Nm). Figure 11. Light-to-racket Installation ###### Figure 9. ulb Installation Nut, hex G8 Z Washer,.500 split lock Z Washer,.500 flat 1.060/.110 Z,G Screw, X4.000 ST hex G5 Z PN

5 8. See Figure 12. Install strain relief to junction box. Install coil-cord to tubing clamp, then install tubing clamp as shown. 11. See Figure 14. In junction box, connect wires. LIGHT TOWER LIGHT LK LK WHT RE WHT/LK WHT/RE RE LUE ROWN LUE WHT/LUE WHT/ORG YELLOW (or ORNGE) ORNGE Figure 12. Junction ox Installation Strain relief Tubing clamp retained in step 6 of Removing Standard Equipment Screw X.500 truss phil 18-8 SS 9. See Figure 13. Install coil-cord through lower strain relief (). Verify enough wire is in junction box to connect to WGO connectors, then tighten strain relief. GREEN (GROUN) GREEN Figure 14. Junction ox Wiring 12. See Figure 15. Install junction box cover ##### ###### Figure 15. Junction ox over Installation Screw, 6-32x.750 pan phil G2 Z over, box, 2 gang, plstc iffused Metal Halide Kit installation is complete. Figure 13. able Installation 10. Install light fixture cord through upper strain relief (). Verify enough wire is in junction box to connect to WGO connectors, then tighten strain relief. PN

6 Installation: Other Vertical Mast MLTs Preparing Unit for Service WRNING urn hazard. Lamps become extremely hot while in use. llow minutes for cooling before handling or lowering mast. Touching a hot lens or fixture can cause severe burns. (000278) 1. Fully retract mast. 2. Place unit on firm, flat surface. 3. lock wheels. 4. Verify unit is OFF, the engine is cool, and the lamps are cool. 5. isconnect negative (-) battery cable. Removing Standard Equipment Unless specified, parts removed in this section do not need to be retained for later installation. 1. See Figure 1. Remove lid of junction box. 2. Inside junction box, disconnect all wires, then loosen strain reliefs, then remove all wires from box. 3. See Figure 16. Remove light fixtures (). Remove crossbar (). Remove junction box (). 4. See Figure 3. Remove bulbs from light fixtures as follows: Remove hardware (). Remove lid () and gasket (). Unfasten bulb support, as illustrated () Finally, remove and retain bulb. 5. See Figure 17. Remove and retain tubing clamp (). Figure 17. Tubing lamp Removal ##### Figure 16. Light Fixture and rossbar Removal IMPORTNT NOTE: When checking or replacing the PN

7 Installing Metal Halide Kit 1. See Figure 18. Install new mounting weldment. Tighten hardware to 20 ft-lb (27.2 Nm). Figure 18. racket Installation Item PN escription ssy bracket MNT vert mast Screw, x 3/000 std hex G5 Z Washer,.375 flat.810/.060 ZY hardened Nut, hex G8 Z 2. See Figure 7. On the light fixture, remove and retain hardware securing sides of lid. 3. See Figure 8. On the light fixture, remove and retain hardware securing top of lid. Remove and retain lid. IMPORTNT NOTE: When checking or replacing the 4. See Figure 9. Install bulbs, as follows. Pinch at () to release spring-clamp brace. Pivot as illustrated (). Install bulb (). Secure bulb with spring-clamp brace as shown () Install lid to new light fixture, as follows. IMPORTNT NOTE: Excessive torque can strip screw heads and damage threads. See Figure 8. Install lid using hardware retained in step 3, lubricating surfaces of rubber washers before installing. Tighten hardware to 19.7 ft-lb (26.7 Nm). See Figure 7. Install hardware retained in step 2. Tighten to 75 in-lb (8.5 Nm). 6. See Figure 10. Install bearings () to light fixture. rrange light fixture so strain relief () faces away from mast. 7. See Figure 11. Install light fixture to mounting weldment. Tighten hardware to 43 ft-lb (58.3 Nm). 8. See Figure 12. Install strain relief to junction box. Install coil-cord to tubing clamp, then install tubing clamp as shown. 9. See Figure 13. Install coil-cord through lower strain relief (). Verify enough wire is in junction box to connect to WGO connectors, then tighten strain relief. 10. See Figure 13. Install light fixture cord through upper strain relief (). Verify enough wire is in junction box to connect to WGO connectors, then tighten strain relief. 11. See Figure 14. In junction box, connect wires. 12. See Figure 15. Install junction box cover. iffused Metal Halide Kit installation is complete. Part No Rev 01/04/ Generac Mobile Products, LL ll rights reserved. Specifications are subject to change without notice. Generac Mobile Products, LL No reproduction allowed in any form without prior written consent 215 Power rive, erlin, WI from PN Generac Mobile Products, LL. GeneracMobileProducts.com