COMBINATION LIGHT TOWER
GENERATOR & WATER TRAILER
MTT20IF4
00900
OPERATING MANUAL
Parts manuals available online! www.magnumpower.com
INTRODUCTION
This manual provides information and procedures to safely operate and maintain the Magnum Power Products LLC
unit. For your own safety and protection from physical injury, carefully read, understand, and observe the safety
instructions described in this manual. Keep a copy of this manual with the unit at all times. Additional copies are
available from Magnum Power Products LLC, or can be found at www.magnumpower.com.The information
contained in this manual was based on machines in production at the time of publication. Magnum Power Products
LLC reserves the right to change any portion of this information without notice.
Read all of the manuals included with the unit. Each manual details specific information regarding items such as
setup, use and service requirements. An engine operator’s manual provides detailed operation and maintenance
procedures for the engine. Additional copies of the engine operator’s manual are available from the engine
manufacturer.
DO NOT MODIFY or use this equipment for any application other than which it was designed for.
Magnum Power Products LLC recommends that a trained and licensed professional perform all electrical wiring and
testing functions. Installation should be in compliance with the National Electrical Code (NEC), state and local
regulations and Occupational Safety and Health Association (OSHA) guidelines.
MAGNUM POWER PRODUCTS LLC
215 Power Drive • Berlin, WI 54923
U.S.A.
Phone: 920-361-4442
FAX: 920-361-4416
Toll Free: 1-800-926-9768
www.magnumpower.com
For technical or parts QUESTIONS, please contact the Magnum Power Products LLC Customer
Support or Technical Support team at 1-800-926-9768. Please have your serial number available.
To ORDER SERVICE PARTS, please contact the dealer from which you purchased the unit, or call
Magnum Power Products LLC to locate a dealer in your area.
Engine Make:__________________________________________
Engine Serial Number:___________________________________
Engine Model Number: __________________________________
Generator Make: _______________________________________
Generator Model Number: ________________________________
Generator Serial Number: ________________________________
Unit Model Number:_____________________________________
Unit Serial Number: _____________________________________
WARNING
CALIFORNIA PROPOSITION 65 WARNING: Diesel engine exhaust and some of its
constituents are known to the state of California to cause cancer, birth defects and
other reproductive harm.
2
TABLE OF CONTENTS
INTRODUCTION ................................................................................................................................ 2
SAFETY NOTES ................................................................................................................................ 5
OPERATING SAFETY ....................................................................................................................... 5
ENGINE SAFETY............................................................................................................................... 6
SERVICE SAFETY............................................................................................................................. 7
TOWING SAFETY.............................................................................................................................. 7
REPORTING TRAILER SAFETY DEFECTS ..................................................................................... 8
SAFETY SYMBOL SUMMARY .......................................................................................................... 9
SPECIFICATIONS............................................................................................................................ 10
UNIT DIMENSIONS ......................................................................................................................... 11
UNIT SERIAL NUMBER LOCATIONS ............................................................................................. 12
COMPONENT LOCATIONS ............................................................................................................ 13
LIGHT TOWER SET UP................................................................................................................... 14
RAISING THE MAST........................................................................................................................ 15
RAISING THE MAST WITH ELECTRIC WINCH OPTION............................................................... 16
MAIN CONTROL PANEL ................................................................................................................. 17
L401 CONTROLLER ........................................................................................................................ 18
CONTROLLER FEATURES AND FUNCTIONS .............................................................................. 18
OPERATOR SCREENS ................................................................................................................... 23
PRESTART CHECKLIST ................................................................................................................. 25
ENGINE BREAK-IN REQUIREMENTS............................................................................................ 26
EMERGENCY STOP SWITCH ........................................................................................................ 26
MANUAL STARTING OF THE UNIT................................................................................................ 26
AUTO (REMOTE) STARTING OF THE UNIT .................................................................................. 27
AUTOMATIC SHUTDOWN ..............................................................................................................28
LIGHT OPERATION......................................................................................................................... 28
VOLTAGE REGULATION ................................................................................................................ 29
DERATING FOR ALTITUDE ............................................................................................................ 29
WET STACKING .............................................................................................................................. 29
RECEPTACLE PANEL..................................................................................................................... 29
REMOTE START TERMINAL BLOCK ............................................................................................. 30
TRANSFER SWITCH ....................................................................................................................... 30
AUTO EXERCISE TIMER ................................................................................................................ 31
SHUTTING DOWN THE UNIT ......................................................................................................... 33
USING THE WATER SUPPLY......................................................................................................... 33
LOWERING THE MAST - MANUALLY ............................................................................................ 34
LOWERING THE MAST - ELECTRIC WINCH OPTION.................................................................. 34
REMOVING THE LIGHTS FOR TRANSPORTATION ..................................................................... 35
TOWING THE UNIT ......................................................................................................................... 35
LIFTING THE UNIT .......................................................................................................................... 36
GENERAL MAINTENANCE .............................................................................................................36
BASIC MAINTENANCE SCHEDULE - ISUZU ENGINE .................................................................. 37
RESETTING THE MAINTENANCE ALARMS.................................................................................. 38
WINCH USE, OPERATION & MAINTENANCE - MANUAL ............................................................. 38
WINCH USE, OPERATION & MAINTENANCE - ELECTRIC ..........................................................39
JACK MAINTENANCE ..................................................................................................................... 40
TRAILER WHEEL BEARINGS ......................................................................................................... 40
LOWER RADIATOR HOSE HEATER OPTION - USE AND MAINTENANCE................................. 40
TROUBLESHOOTING THE LIGHTS ............................................................................................... 41
TROUBLESHOOTING AUTOMATIC SHUTDOWN CONDITIONS ................................................. 41
MAST LIGHT CONNECTIONS ........................................................................................................ 42
AC WIRING DIAGRAM ................................................................................................................... 43
AC WIRING DIAGRAM - RECEPTACLE PANEL ............................................................................ 44
AC WIRING DIAGRAM - RECEPTACLE PANEL OPTIONS (1 OF 2)............................................. 45
AC WIRING DIAGRAM - RECEPTACLE PANEL OPTIONS (2 OF 2)............................................. 46
DC WIRING DIAGRAM .................................................................................................................... 47
Page
3
DC WIRING DIAGRAM - ELECTRIC WINCH OPTION ...................................................................48
DC WIRING DIAGRAM - INTERIOR LIGHT OPTION ..................................................................... 49
DC WIRING DIAGRAM - BATTERY DISCONNECT OPTION......................................................... 49
DC WIRING DIAGRAM - BATTERY CHARGER OPTION............................................................... 49
TRAILER LIGHTS WIRING DIAGRAM ............................................................................................ 50
SERVICE LOG ................................................................................................................................. 51
4
SAFETY NOTES
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible injury or death.
This manual contains DANGERS, WARNINGS, CAUTIONS, NOTICES and NOTES which must be
followed to prevent the possibility of improper service, damage to the equipment, personal injury or death.
The following formatting options will apply when calling the readers attention to the DANGERS, WARNINGS, CAUTIONS, NOTICES and NOTES.
INDICATES A HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN
Indicates a hazardous situation which, if not avoided, could result in death or serious
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
DANGER
DEATH OR SERIOUS INJURY.
WARNING
injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in property or equipment
damage.
Note: Notes contain additional information important to a procedure and will be found within the regular text body
of this manual.
OPERATING SAFETY
Before using the unit be sure to read and understand all of the instructions provided with the unit. This
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
and controls. Inexperienced operators should receive instruction from someone familiar with the equipment
before being allowed to operate or set up the unit. The following points should be practiced at all times:
• The area immediately surrounding the unit should be dry, clean, and free of debris.
• Position and operate the unit on a firm, level surface.
• NEVER start a unit in need of repair.
• ALWAYS lower the mast when not in use, or if high winds or electrical storms are expected in the area.
• Make certain the unit is well grounded and securely fastened to a good earthen ground. Follow the
National Electrical Code (NEC), state and local regulations.
• The mast extends up to 31.5 ft (9.6 m). ALWAYS make sure the area above the unit is open and clear
of overhead wires and obstructions.
• Keep area around the mast clear of people while raising and lowering the mast.
• Keep all body parts, clothing and other loose items clear of the winch, cables and pulleys during
operation.
• Bulbs become extremely hot during use. Allow them to cool 10-15 minutes before handling.
• NEVER raise or lower the mast while lights are in operation.
5
• ALWAYS extend the outriggers and level the unit before raising the mast. DO NOT retract the outriggers
while the mast is up.
• If for any reason any part of the mast hangs up or the winch cable develops slack while raising or
lowering the mast, STOP immediately and contact an authorized service representative.
• NEVER remove safety pin or pull mast locking pin while the mast is up.
• NEVER use the unit if insulation on the electrical cord is cut or worn through.
• NEVER operate the lights without protective lens covers in place or with a lens cover that is cracked
or damaged.
• Only use mild soap and water to clean the lens covers. Other chemicals may have an adverse effect
on the glass.
• NEVER operate a unit while tired, distracted, or under the influence of drugs or alcohol.
• NEVER use water in the supply tank for human consumption. It is not made of food grade material.
• ALWAYS keep the water tank cover in place. Stay out of tank.
• Do not drive over the hoses while they are pressurized or while the pump is running.
• NEVER leave the unit unattended while the pump is running.
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 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 ventilation unless exhaust hoses are used. Diesel
engine exhaust contains carbon monoxide, a deadly, odorless and colorless gas which, if inhaled,
can cause nausea, fainting or death. Make sure engine exhaust cannot seep into closed rooms or
ventilation equipment.
• DO NOT operate the unit on a combustible surface.
• 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.
• DO NOT touch or lean against hot exhaust pipes or engine cylinders.
• DO NOT clean air filter with gasoline or other types of low flash point solvents.
• DO NOT remove engine coolant cap while engine is hot.
• DO NOT operate the unit without a functional exhaust system. Prolonged exposure to sound levels
in excess of 85 dB(A) can cause permanent hearing loss. Wear hearing protection when working
around a running engine.
• Keep area around exhaust pipes and air ducts free of debris to reduce the chance of an accidental fire.
• Batteries contain sulfuric acid which can cause severe injury or death. Sulfuric acid can cause eye
damage, burn flesh or eat holes in clothing. Protective eye wear and clothing are necessary when
working on or around the battery. Always disconnect the negative (-) battery cable from the
corresponding terminal before performing any service on the engine or other components.
• Shut the engine down if any of the following conditions exist during operation:
1. Noticeable change in engine speed.
2. Loss of electrical output.
3. Equipment connected to the generator overheats.
4. Sparking occurs.
5. Engine misfires or there is excessive engine/generator vibration.
6
6. Protective covers are loose or missing.
7. If the ambient air temperature is above 120°F (49°C).
SERVICE SAFETY
This unit uses high voltage circuits capable of causing serious injury or death. Only a qualified electrician
should troubleshoot or repair electrical problems occurring in this equipment.
• Before servicing, make sure the Control Power switch and circuit breakers are in the OFF (O) position,
and the negative terminal on the battery is disconnected. NEVER perform even routine service (oil/
filter changes, cleaning, etc.) unless all electrical components are shut down.
• NEVER allow water to accumulate around the base of the unit. If water is present, DO NOT service.
• NEVER service electrical components if clothing or skin is wet. If the unit is stored outside, check the
engine and generator for any moisture and dry the unit before use.
• NEVER wash the unit with a power washer or high pressure hose.
• Open the main circuit breaker before disconnecting battery cables.
• Keep all body parts, clothing, and other loose items away from moving parts on the unit.
• 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 unit safely. Always remain aware of the
position of other people around when lifting the unit.
• NEVER start the unit under load. The circuit breakers must be in the “OFF” position when starting the
unit.
• ALWAYS disconnect the negative (-) battery cable from the corresponding terminal before performing
any service on the engine, generator or any other components. Remove the negative (-) battery cable
from the corresponding terminal if the unit is to be stored or transported.
• Replace all guards and safety devices immediately after servicing.
• Wear heavy leather gloves when handling winch cables. Never let cables slip through bare hands.
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.
• Check that the hitch and coupling on the towing vehicle are rated equal to, or greater than, the trailer's
Gross Vehicle Weight Rating (GVWR).
• Check tires on trailer for tread wear, inflation, and condition.
• NEVER tow trailer using defective parts. Inspect the hitch and coupling for wear or damage.
• Make sure the trailer hitch and the coupling are compatible. Make sure the coupling is securely fastened
to the vehicle.
• Connect safety chains in a crossing pattern under the tongue and ATTACH THE BREAKAWAY
CABLE TO THE REAR BUMPER OF THE TOWING VEHICLE. Do not attach the cable to the trailer
hitch.
• Make sure directional and brake lights on the trailer are connected and working properly.
• Check that all lug nuts holding wheels on are tight and none are missing.
• Maximum recommended speed for highway towing is 45 mph (72 km/h). Recommended off-road
towing speed is not to exceed 10 mph (16 km/h) or less, depending on terrain.
7
• When towing, maintain extra space between vehicles and avoid soft shoulders, curbs and sudden
lane changes. If you have not pulled a trailer before, practice turning, stopping, and backing up in an
area away from heavy traffic.
• Towing the unit with water in the tank will adversely affect handling of towing vehicle, specifically
maneuvering corners, accelerating, and braking. Ensure operator has experience with towing unit.
• Maximum recommended towing speeds for the unit are as follows:
1. With the tank empty, improved road: 55 mph (89 km/h)
2. With the tank full, improved road: 45 mph (72 km/h)
3. With the tank 1/2 full, improved road: 45 mph (72 km/h)
4. Any towing on unimproved roads: 20 mph (32 km/h) or less
• Before towing the trailer, check that the weight of the trailer is equal across all tires. A large angle
between the trailer and tow vehicle will cause more weight to be carried by one axle, which could
cause premature wear on the tires and axles and cause potentially unsafe operating conditions. Adjust
the angle of the trailer tongue to keep the trailer as level as possible.
• The trailer is equipped with hydraulic surge brakes or electric surge brakes. Check the operation of
the brakes by braking the vehicle at a slow speed before entering traffic. Both the trailer and the vehicle
should brake smoothly. If the trailer seems to be pushing, check the level in the surge brake fluid
reservoir.
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 Magnum Power Products
LLC.
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 Magnum Power 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 Jersey Avenue S.E.
Washington, DC 20590
You can also obtain other information about motor vehicle safety from http://www.safercar.gov.
8
SAFETY SYMBOL SUMMARY
This equipment has been supplied with numerous safety and operating decals. These decals provide important
operating instructions and warn of dangers and hazards. Replace any missing or hard-to-read decals and use care
when washing or cleaning the unit. Decal placement and part numbers can be found in the parts manual. Below is
a summary of the intended meanings for the symbols used on the decals.
Safety alert symbol;
used to alert you
to potential hazards.
Hot surface(s) nearby.
Dangerous voltage may
be present.
Ultraviolet radiation
hazard; operate only
with lens intact.
Check diesel fuel fill
level.
Read and understand
the operator’s manual
before operating.
> 60 mph
15 MIN
Asphyxiation hazard;
operate in well ventilated area.
Burn/scald hazard;
pressurized steam.
Wind hazard; do not set
up in wind speeds
greater than 60 mph
(95 km/h).
Electrical storm hazard.
Allow to cool.
Wait 15 minutes.
Belt/entanglement
hazard; keep body parts
clear of this area.
Fan hazard; keep body
parts clear of this area.
Crush hazard; keep
body parts clear of
this area.
Do not operate near
power lines. Contact with
power lines can cause
electrocution.
Do not remove guard.
Fire/explosion hazard;
keep open flames
away from unit.
STOP
Stop engine.
Anchor/tie down point.
Do not drink the water.
Disconnect battery
before servicing.
Unit electrical ground.
Automatic Start.
Non-potable water.
00901
9
SPECIFICATIONS
MAGNUM MODEL MTT20IF4
Engine
Make/Brand.......................................................................................................................... Isuzu
Model ...................................................................................................................................4LE2TAGV-03
EPA Tier ...............................................................................................................................4f
Horsepower - prime hp (kW) ...............................................................................................36.2 (27.0)
Horsepower - standby hp (kW)............................................................................................ 40.2 (30.0)
Operating Speed rpm ..........................................................................................................1800
Displacement in3 (L) ............................................................................................................133 (2.19)
Cylinders - qty ......................................................................................................................4
Fuel Consumption - 100% prime gph (Lph)........................................................................2.1 (7.8)
Battery Type - Group Number .............................................................................................. 24
Battery Voltage (Quantity per Unit) ......................................................................................12V (1)
Battery Rating ......................................................................................................................720 CCA
Generator
Make/Brand..........................................................................................................................Marathon Electric
Model ...................................................................................................................................334CSA3028
Type, Insulation.................................................................................................................... Brushless, H
Generator Set (Engine/Generator)
1Ø - Standby kW (kVA) ......................................................................................................20.0 (20.0)
Amps - 1Ø Standby - 240V A ...............................................................................................83
1Ø - Prime kW (kVA) ..........................................................................................................19.0 (19.0)
Amps - 1Ø Prime - 240V A................................................................................................... 79
Frequency Hz ......................................................................................................................60
Power Factor........................................................................................................................1 (1Ø)
Pump
Make/Model .........................................................................................................................SHURFlo
Flow Rate gpm (Lpm) .........................................................................................................3.3 (12.5)
Flow Rate at Hose Bibb gpm (Lpm).................................................................................... 3.0 (11.4)
Weights
Dry Weight lbs (kg)..............................................................................................................5181 (2350)
Operating Weight lbs (kg) ...................................................................................................10921 (4954)
Capacities
Fuel Tank Volume gal (L) ....................................................................................................246 (931)
Usable Fuel Volume gal (L) ................................................................................................229 (867)
Water Tank Volume gal (L) .................................................................................................500 (1895)
Maximum Run Time hrs .....................................................................................................109
AC Distribution
Circuit Breaker Size .............................................................................................................100
Voltage Selection .................................................................................................................N/A
Voltage Regulation...............................................................................................................+/-1%
Voltages Available 1Ø ..........................................................................................................120, 240
Voltages Available 3Ø ..........................................................................................................N/A
Lighting
Lighting Type, Ballast Type ...................................................................................................Metal Halide, Coil & Core
Lumens.................................................................................................................................440,000
Coverage acres (m2)............................................................................................................5 - 7 (20,234 - 28,328)
Trailer
Number of Axles...................................................................................................................2
Capacity - Axle Rating lbs (kg) ...........................................................................................6000 (2722)
Tire Size in ..........................................................................................................................16
Brakes..................................................................................................................................Surge
Hitch - Standard ...................................................................................................................3" Ring
Maximum Tire Pressure psi ................................................................................................75
Specifications are subject to change without notice.
10
UNIT DIMENSIONS
C
B
A
D
ABCD
00902
MTT20IF4
Specifications are subject to change without notice.
210 in
(5.3 m)
83 in
(2.1 m)
31.5 ft
(9.6 m)
86 in
(2.18 m)
11
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.
Unit ID Tag
Located on inside
of front panel
Manufactured by Magnum Power Products, LLC.,
a subsidiary of Generac Power Systems, Inc.
(920) 361-4442 (800) 926-9768
Country of Origin
Manufacturing Code
1 ph. 1.0PF 3 ph. .8PF 3 ph. 1.0PF
KW
KVA
V
A
Serial Number
Model
Weight (lbs/kg) RPM/Frequency
Rating
FOR ELECTRICAL EQUIPMENT
ONLY. POUR MATERIAL
ELECTRIQUE SEULEMENT.
209649
Form: SFC626B
Ins. Class
VIN Tag
MANUFACTURED BY/FABRIQUE PAR: Magnum Power Products LLC DATE: 00/0000
GVWR/PNBV: 000KG (0000LBS) COLD INF. PRESS./
PRESS. DE
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 APPLICABLES EN VERTU DU REGLEMENT SUR LA SECURITE DES VEHICULES AUTOMOBILES DU CANADA EN VIGUEUR A LA DATE SA
FABRICATION.
00000000000000000
V.I.N./N.I.V.:
XXX000
MODEL:
TYPE:
TRAILER
TIRE AND LOADING INFORMATION
RENSEIGNEMENTS SUR LES
PNEUS ET LE CHARGEMENT
The weight of cargo should never exceed 0000KG (0000LBS)
Le poids du chargement ne doit jamais depasser 0000KG (0000LBS)
SEE OWNER’S
MANUAL FOR
ADDITIONAL
INFORMATION
VOIR LE
MANUEL DE
L’USAGER
POUR
PLUS DE
RENSEIGNEMENTS
00903
12
COMPONENT LOCATIONS
Emergency
Stop Switch
Receptacle
Grounding
Stud
Panel
Leveling
Jack
Control
Panel Access
Engine / Battery
Access
Forklift
Pockets
LEFT SIDE
Engine
Exhaust
Fuel
Fill
Forklift
Pockets
Water Tank
Cover
Leveling
Jack
Hose
Bibbs
Leveling
Jack
Forklift
Pockets
Radiator Access
(on roof panel)
Forklift
Pockets
RIGHT SIDE 00904
Engine
Access
Leveling
Jack
13
LIGHT TOWER SET UP
1. For maximum light coverage, locate the unit at ground level or in a spot higher than the area being illuminated
by the lamps.
WARNING
The mast extends up to 31.5 ft (9.6 m). Make sure the area above the unit is open and
clear of overhead wires and obstructions. Do not set up the unit if high winds or
storms capable of producing lightning are expected in the area.
E
D
C
D
B
F
DETAIL C
E
D
A
DETAIL D
DETAIL E
00905
2. Place the unit on firm ground that is relatively flat, then block the wheels to keep it from moving (A). This will
make it easier to level the unit.
3. Turn the tongue jack handle clockwise to raise the trailer tongue off of the towing vehicle (B).
4. Connect a good earthen ground to the grounding stud on the frame of the trailer near the trailer tongue (C).
Note: Refer to local codes for proper grounding requirements.
5. Pull the locking pins on the four leveling jacks (D), rotate them so the jack feet are toward the ground, and insert
the locking pins again to secure the jacks. Adjust all four jacks by turning their handles clockwise until they are
firmly in contact with the ground and the unit is as level as possible.
6. 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 (E) and aiming them in the desired direction. Tighten the hardware
completely and make sure the lamps are connected to the junction box (F).
14
RAISING THE MAST
1. Set up and level the unit. Refer to “Light Tower Set
Up” on page 14.
WARNING
The unit must be leveled before raising
the mast. Failure to level the unit will
severely reduce the stability and could
allow the unit to tip and fall.
DETAIL A
DETAIL C
2. Remove mast cradle locking pin from mast cradle (A).
3. Check the mast cables for excessive wear or damage. Make sure the cables are properly centered in
each pulley (B). Check the electrical cord for damage.
WARNING
Do not start the unit if insulation on the
electrical cord is cut or worn through.
Bare wires in contact with the mast or
frame may energize the 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.
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 automatically. Secure the lock
with the safety pin (E).
STOP
B
DETAIL E
G
A
H
F
D
C,E
B
DETAIL G
00906
6. After the mast is up and locked into place, use the upper mast winch (F) to telescope the mast to the desired
height. Extend the mast slowly, making sure the electrical cord is extending at the top sections of the mast. If,
for any reason, the winch cable begins to develop slack or any of the mast sections get stuck, STOP
IMMEDIATELY and contact an authorized service center.
CAUTION
Do not extend the mast beyond the colored mark on the middle mast tube (G).
7. The mast can be rotated by loosening the mast rotation knob at the bottom of the mast (H). Turn the mast until
the lights face in the desired direction and then tighten the mast rotation knob to secure the mast in position.
WARNING
Never raise or lower the mast while the unit is operating. Never remove the safety pin or
release the mast lock while the mast is up. Releasing the lock will cause the mast to fall.
15
RAISING THE MAST WITH ELECTRIC WINCH OPTION
1. Set up and level the unit. Refer to “Light Tower Set
Up” on page 14.
WARNING
The unit must be leveled before raising
the mast. Failure to level the unit will
severely reduce the stability and could
allow the unit to tip and fall.
2. Remove mast cradle locking pin from mast cradle (A).
DETAIL C
DETAIL D
3. Check the mast cables for excessive wear or damage. Make sure the cables are properly centered in
each pulley (B). Check the electrical cord for damage.
WARNING
Do not start the unit if insulation on the
electrical cord is cut or worn through.
Bare wires in contact with the mast or
frame may energize the 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.
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 until the mast lock is engaged. The mast lock
bar should snap into place automatically. Secure the
lock with the safety pin (E).
Note: On units with the electric winch option, a limit switch
on the mast tube will disconnect power to the lower electric winch to prevent deadheading the winch.
B
F
D
H
B
G
A
DETAIL E
STOP
DETAIL G
C,E
DETAIL F
DETAIL H
00907
6. Press and hold the upper winch control switch (F) upward to telescope the mast to the desired height. Extend
the mast slowly, making sure that the coiled electrical cord is extending at the top sections of the mast. If, for
any reason, the winch cable begins to develop slack or any of the mast sections get stuck, STOP IMMEDIATELY
and contact an authorized service center.
CAUTION
Do not extend the mast beyond the colored mark on the middle mast tube (G). On units equipped
with the electric winch option, a limit switch on the main mast section will disconnect power to the
upper electric winch to prevent overextending the mast.
7. The mast can be rotated by loosening the mast rotation knob at the bottom of the mast (H). Turn the mast until
the lights face in the desired direction and then tighten the mast rotation knob to secure the mast in position.
WARNING
Never raise or lower the mast while the unit is operating. Never remove the safety pin or
release the mast lock while the mast is up. Releasing the lock will cause the mast to fall.
16
MAIN CONTROL PANEL
1
5
4
3
DC
BREAKER
NEUTRAL BONDED TO FRAME
1. L401 CONTROLLER: Refer to “L401 Controller” on page 18.
MAIN
BREAKER
240V
ON
2
ON
00896
2. MAIN CIRCUIT BREAKER: This 240V (100A) breaker will disconnect power to the lights and the receptacles.
3. DC BREAKER: Circuit breaker (10A) for the engine electrical system.
4. AC/LIGHT BREAKERS (4): Circuit breakers for the lights.
5. CONTROL POWER SWITCH: Powers the L401 controller.
17
L401 CONTROLLER
The L401 controller is an auto start controller that monitors the unit and indicates operational status and fault
conditions. The controller can be programmed to automatically start or stop based on time schedule, fault condition,
or load demand.
The controller constantly monitors vital generator and engine functions for a number of preprogrammed alarm and
fault conditions. When a fault condition occurs, the engine can be shut down automatically and the LCD window will
show the fault that caused the shutdown. To resume operation, the fault condition must be resolved.
This controller also records a history of unit performance, which may be viewed at any time and will not be lost when
the controller is powered down.
Menu
Navigation
Stop/Reset
Mode LED
Stop/Reset
Mode
LCD Window
Auto Mode
Manual/Start
Mode LED
Manual/Start
Mode
00851
CONTROLLER FEATURES AND FUNCTIONS
THE LIQUID CRYSTAL DISPLAY (LCD) WINDOW
This window will display the various operator screens. By viewing these screens, the operator will be able to monitor
both the engine and generator status while the unit is running.
Screen
Icon
Active
Config
FPE/Auto
Run
This table lists the non-alarm icons possible to be displayed on the various operator screens.
Screen Data Unit
Alarm Icon
Screen Data Unit
Mode Icon
Screen Data Unit
Light Output Icons
Icon Details
Screen Icons
The default home page which displays Generator voltage and the Auto Run icon
18
Icon Details
Generator voltage and frequency screen
Current and load screen
Engine speed screen
Hours run screen
Battery voltage screen
Oil pressure screen
Coolant temperature screen
Fuel sender screen
Event log
Current time held in the unit
The current valve of the scheduler run time and duration
ECU diagnostic trouble codes
Oil filter maintenance timers
Air filter maintenance timers
Fuel filter maintenance timers
Active Configurations
Main configuration
Alternative configuration
Front Panel Editor (FPE) / Auto Run Icons
Remote start input is active
Low battery run is active
Scheduled run is active
Mode Icons
Engine is at rest and the unit is in Stop mode
Engine is at rest and the unit is in Auto mode
Engine is at rest and the unit is waiting for a manual start
19
Icon Details
A timer is active (i.e. cranking time, crank rest, etc.)
Engine is running, and all timers have expired, either on or off load. The animation speed is reduced
when running in Idle mode.
Unit is in the front panel editor
USB connection is made to the controller
Configuration file or engine file is corrupted
Light Output Icons
Corresponding light output has been configured and is not active
Corresponding light output has been configured and is active
A timer to delay the light output is activating or de-activating
This table lists the possible alarm icons displayed on the operator screens. In the event of a warning alarm, the LCD
only displays the alarm icon. In the event of an electrical trip or shutdown alarm, the controller displays the alarm
icon and the Stop mode button LED begins to flash. If multiple alarms are active at the same time, the alarm icon
automatically cycles through all the appropriate icons to indicate each alarm which is active.
Icon Fault Description
Warming Alarm Icons
The controller has detected a condition that indicates that the engine is
running when it has been instructed to stop.
Fail To Stop
Note: ‘Fail to Stop’ could indicate a faulty oil pressure sensor. If engine is
at rest, check oil sensor wiring and configuration.
Low Fuel Level
Battery Under Voltage
Battery Over Voltage The DC supply has risen above the high volts setting level.
Generator Under Voltage
Generator Over Voltage
Generator Under Frequency
Generator Over Frequency
The level detected by the fuel level sensor is below the low fuel level setting.
The DC supply has fallen below or risen above the low volts setting
level.
The generator output voltage has fallen below the pre-set pre-alarm setting after the Safety On timer has expired.
The generator output frequency has risen above the pre-set pre-alarm
setting.
The generator output frequency has fallen below the pre-set pre-alarm
setting after the Safety On timer has expired.
The generator output frequency has risen above the pre-set pre-alarm
setting.
20
CAN ECU Fault The engine ECU has detected an alarm.
CAN Data Fail
Immediate Over Current The measured current has risen above the configured trip level.
The controller is configured for CAN operation and does not detect data
on the engine Can data link.
Icon Fault Description
Delayed Over Current
Low Current
Oil Filter Maintenance Alarm Maintenance due for oil filter.
Air Filter Maintenance Alarm Maintenance due for air filter.
The measured current has risen above the configured trip level for a
configured duration.
The measured current has fallen below the configured trip level. This is
used to detect lamp failure.
Fuel Filter Maintenance
Alarm
Engine High Temperature
Low Fuel Level
Delayed Over Current
Low Current
Fail To Start
Low Oil Pressure
Under Speed The engine speed has fallen below the under speed pre-alarm setting.
Over Speed The engine speed has risen above the over speed pre-alarm setting.
Maintenance due for fuel filter.
Electrical Trip Alarm Icons
The controller detects that the engine coolant temperature has
exceeded the high engine temperature pre-alarm setting level after the
Safety On timer has expired.
The level detected by the fuel level sensor is below the low fuel level setting.
The measured current has risen above the configured trip level for a
configured duration.
The measured current has fallen below the configured trip level. This is
used to detect lamp failure.
Shutdown Alarm Icons
The engine has failed to start after the configured number of start
attempts.
The controller detects that the engine oil pressure has fallen below the
low oil pressure pre-alarm setting level after the Safety On timer has
expired.
Low Fuel Level
Battery Under Voltage
Battery Over Voltage The DC supply has risen above the high volts setting level.
Generator Under Voltage
Generator Over Voltage
Generator Under Frequency
Generator Over Frequency
CAN ECU Fault The engine ECU has detected an alarm.
CAN Data Fail
Emergency Stop The emergency stop switch has been depressed.
The level detected by the fuel level sensor is below the low fuel level setting.
The DC supply has fallen below or risen above the low volts setting
level.
The generator output voltage has fallen below the pre-set pre-alarm setting after the Safety On timer has expired.
The generator output frequency has risen above the pre-set pre-alarm
setting.
The generator output frequency has fallen below the pre-set pre-alarm
setting after the Safety On timer has expired.
The generator output frequency has risen above the pre-set pre-alarm
setting.
The controller is configured for CAN operation and does not detect data
on the engine Can data link.
21
Icon Fault Description
Delayed Over Current
Low Current
Oil Filter Maintenance Alarm Maintenance due for oil filter.
Air Filter Maintenance Alarm Maintenance due for air filter.
The measured current has risen above the configured trip level for a
configured duration.
The measured current has fallen below the configured trip level. This is
used to detect lamp failure.
Fuel Filter Maintenance
Alarm
Warnings are non-critical alarm conditions and do not affect the operation of the generator system, they serve to
draw the operator’s attention to an undesirable condition. By default, warning alarms are self-resetting when the fault
condition is removed.
Electrical trips are latching and stop the generator but in a controlled manner. On initiation of the electrical trip
condition, the controller de-energizes all the outputs, including the lights, to remove the load from the generator.
Once this has occurred, the controller start the cooling timer and allows the engine to cool off-load before shutting
down the engine.
Shutdown alarms are latching and immediately stop the generator. On initiation of the shutdown condition, the
controller de-energized all the outputs, including the lights, to remove the load from the generator. Once this has
occurred, the controller shuts the generator set down immediately to prevent further damage.
Note: The alarm condition must be rectified before a reset will take place. If the alarm condition remains, it is not
possible to reset the unit. The exception to this is the Low Oil Pressure alarm and similar ‘active from safety on’
alarms, as the oil pressure is low with the engine at rest.
To remove the fault of the latching alarms, refer to “Resetting the Maintenance Alarms” on page 38.
Note: The LCD backlight is on if the unit has sufficient voltage while the unit is turned on, unless the unit is cranking
for which the backlight is turned off.
Maintenance due for fuel filter.
If the controller is left in Stop mode without pressing any buttons for 30 minutes, the controller enters Power Save
mode. To ‘wake’ the controller, press the Stop/Reset (O) button.
AUTO MODE
This button will place the unit in Auto mode. This mode allows the generator to operate fully automatic, starting and
stopping as required with no user intervention.
MANUAL/START MODE LED
This LED will be lit when the unit is in Manual mode.
MANUAL/START MODE
This button will start the engine and place the unit in Manual mode, provided there are no shutdown errors, and the
engine satisfies the start status.
STOP/RESET MODE
This button will shut down the unit and put the controller into Stop mode, whether in Manual mode or Auto mode.
22
CAUTION
In case of an emergency, always press the emergency stop switch located on the side of
the unit to stop the engine immediately. The Stop/Reset (O) button may delay the engine
shutdown if stop faults exist.
To prevent damage to the generator and connected equipment, remove all loads from the
generator by opening all circuit breakers (turn to the OFF (O) position) before pressing the
Stop/Reset (O) button.
STOP/RESET MODE LED
This LED will be lit when the unit is in Stop mode and will flash when an Electrical Trip and Shutdown Fault has occurred.
MENU NAVIGATION
These buttons (↑, ↓) are used to navigate through the different operator screens.
OPERATOR SCREENS
The information displayed on the operator screens can be used to identify, diagnose and troubleshoot unit shutdown
conditions and poor unit performance.
To enter the navigation menu, use the following procedure:
1. Press both the ↑ and ↓ buttons simultaneously.
00852
2. To select the required icon, press the ↑ button to cycle right and the ↓ button to cycle left until the desired operator
screen section is reached.
3. Once the desired icon is at the top, press the Auto button to enter that operator screen section.
Note: If the Auto button is not pressed after 5 minutes of inactivity, the display automatically returns to the Home icon.
Icon Description
Home and generator voltage and frequency operator screens
Generator current and load operator screens
Engine screens
Controller screens
23
Icon Description
Mast and light screens
Engine DTCs (Diagnostic Trouble Codes) if active
Event log
HOME SCREEN
The Home screen is the default screen of the controller and will display after the controller has powered up. The
controller will automatically return to this screen from any other screen after a period of inactivity.
00897
ENGINE SCREENS
The Engine screens will display the speed, run time, battery voltage, coolant temperature, oil pressure, fuel level
and when maintenance is due for the oil, air, and fuel filters.
GENERATOR SCREENS
The Generator screens will display the voltage, frequency, current, load per phase, total load, power factor per phase,
and average power factor.
CONTROLLER SCREENS
The Info screens contain information about the controller such as the controller’s date and time, the scheduler settings,
the product description and USB identification number, and the application and engine version.
MAST AND LIGHT SCREENS
The mast and light screens gives access to raise and lower the mast along with turning on and off the lights. For
light operation, refer to “Light Operation” on page 28.
Note: Mast operation through the controller is only available for vertical mast units.
ENGINE DTCS
This screen displays active Diagnostic Trouble Codes (DTC) only if the engine ECU generating a fault code. These
alarm conditions are detected by the engine ECU and displayed by the controller.
To view the engine DTC(s), press both the ↑ and ↓ buttons simultaneously, the navigation menu is then displayed.
Once entered, cycle to the DTC section and enter.
To view the active DTC(s) alarms, repeatedly press the ↑ and ↓ buttons until the LCD window displays the alarm.
Continuing to press the ↑ and ↓ buttons will cycle through the alarms.
24
To exit the active DTC(s) alarm section, press the ↑ and ↓ buttons simultaneously to enter the navigation menu. Once
entered, cycle to the desired operator screen.
Icon Fault DTC Description
Check Engine Fault
Low Oil Pressure
Under Speed
Over Speed
Low Fuel Level
Battery Under/Over Voltage
EVENT LOG
The controller’s event log displays a list of the last 15 record electrical trip or shutdown events and the engine hours
at which they occurred. Once the log is full, any subsequent electrical trip or shutdown alarms overwrites the oldest
entry in the log. Hence, the log always contains the most recent shutdown alarms.
The engine ECU has detected a fault not recognized by the controller, contact the engine manufacturer for support.
The engine ECU has detected that the engine oil pressure has
fallen below its configured low oil pressure alarm level.
The engine ECU has detected that the engine speed has fallen
below its configured under speed alarm level.
The engine ECU has detected that the engine speed has risen
above its configured over speed alarm level.
The engine ECU has detected that the engine’s fuel level has
fallen below its configured low fuel level alarm.
The engine ECU has detected that the engine’s DC supply has
fallen below or risen above its configured alarm level.
To view the event log, press both ↑ and ↓ buttons simultaneously, the navigation menu is then displayed. Once
entered, cycle to the event log section and press the Auto button to enter. Repeatedly press the ↑ or ↓ buttons until
the LCD window displays the desired event.
Continue to press down the ↑ or ↓ buttons to cycle through the past alarms, after which they display shows the most
recent alarm and the cycle begins again.
To exit the event log, press the ↑ and ↓ buttons simultaneously to enter the navigation menu. Once entered, cycle
to the desired operator screen.
PRESTART CHECKLIST
Before starting the unit, all items in the prestart checklist must be completed.
Read and understand ALL safety sections at the beginning of this manual.
Ensure all maintenance procedures are up to date. For more information, refer to “General
Maintenance” on page 37 and “Basic Maintenance Schedule - Isuzu Engine” on page 37.
The unit must be level.
The unit must be dry. Check for any water inside, on, or near the unit; dry if needed.
Ensure the unit is properly grounded to a good earthen ground. Installation should be in compliance
with the National Electrical Code (NEC), state and local regulations.
Switch the Control Power switch to the OFF (O) position.
Switch all circuit breakers to the OFF (O) position.
Inspect all electrical cords; repair or replace any that are cut, worn, or bare.
Ensure 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” on page 37.
Ensure engine 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.
25
Ensure all covers are in place and secure.
Ensure the emergency stop switch is pulled out.
ENGINE BREAK-IN REQUIREMENTS
Note: The EPA final tier 4 Isuzu engines have an engine break-in duration that will prohibit the unit from providing
rated standby power upon factory delivery. The unit is tested at the factory and is initially capable of a prime standby
power output. The engine performance will increase to 95% of full rated power during the first 20 hours of loaded
operation. The unit will provide full rated power after the complete engine break-in period of 70 hours of loaded
operation.
Operate the engine at heavy loads (60-90% [24-36kW] of rated output maximum) as much as possible during the
break-in period. If the engine has spent significant time at idle, constant speed(s) and/or light load or if makeup oil
is required, a longer break in period may be needed. Refer to the engine operator’s manual for a full description of
necessary procedures on the addition of oil and extension of the break-in period. For more information on regular
maintenance intervals, refer to “Basic Maintenance Schedule - Isuzu Engine” on page 37.
EMERGENCY STOP SWITCH
The unit is equipped with one emergency stop switch. For location of the emergency
stop switch, refer to “Component Locations” on page 13. The red switch is clearly
labeled “EMERGENCY STOP.” The switch can be accessed and activated with all
doors closed and locked.
G
E
R
N
E
M
E
C
Y
S
T
P
Activate the emergency stop switch by pushing the red button in until it locks down.
O
This will open the fuel circuit, shutting down the engine. The switch will remain closed
until it is pulled out.
00230
Use the emergency stop switch only when the unit must be shut down immediately. For any
other shut down, refer to “Shutting Down the Unit” on page 32.
MANUAL STARTING OF THE UNIT
All units equipped with the L401 controller will initially start up in Stop mode. Use the following procedure to start the
generator in Manual mode:
1. Check that the main circuit breaker is in the OFF (O) position. Make sure the individual circuit breakers for each
of the lights are pushed in to the reset position.
2. Move the Control Power switch to the ON (I) position.
3. When the controller powers up, the Home screen will
be displayed and the controller will be in Stop mode
as indicated by the Stop LED being lit. Press the Start
button to initiate the startup procedure and start the
engine, provided there are no engine faults
preventing the unit from starting. The Start LED will
now become lit.
Note: The controller can be started from any screen. It
may take a few seconds for the engine to run smoothly
and reach its governed operating speed.
BREAKER
DC
NEUTRAL BONDED TO FRAME
MAIN
BREAKER
240V
ON
ON
26
00898
4. If the engine does not start after the first cranking attempt, the engine will pause for 15 seconds to allow the
starter to cool. The engine will make two more attempts to start for a total of three crank cycles.
Note: The controller backlight will go out when the engine is cranking.
5. Should the engine not start and run within three starting cycles, the LCD window will show the Fail to Start alarm
icon ( ). The starting sequence may be repeated after the starter has had a minimum of two minutes to cool.
Pressing the Stop button will clear the alarm and reset the controller.
6. Once the engine starts, it will immediately begin speeding up to a constant 1800 rpm. The engine may hunt or
change speeds until operating speed is reached. After a few minutes of operation, the engine will be warmed
up and the operator screens will show engine and generator operating parameters. The animated engine running
icon ( ) will be displayed.
7. Check the generator for excessive noise or vibration and any coolant, oil, or fuel leaks before applying any loads.
8. Check that the frequency (Hz) is correct on the Generator screen. With no loads connected to the generator,
the frequency should read approximately 60 Hz, depending on the type of engine governing used.
9. Once the engine is running, allow it to reach normal operating temperature before switching on any loads.
10. If all wiring connections have been made correctly, switch the main circuit breaker to the ON (I) position and then
add any loads attached to the receptacles by switching the respective circuit breaker to the ON (I) position. You
will notice a slight change in engine sound when a load is applied to the unit.
AUTO (REMOTE) STARTING OF THE UNIT
Auto mode is used when the unit is started from a location other than the control panel by using a transfer switch.
Auto (remote start) is the normal setting when the generator is being used as a standby power supply. Before putting
the unit in the Auto mode, review the “Prestart Checklist” on page 25 and “Manual Starting of the Unit” on page 26.
Also following any warnings and information on isolating the generator with a transfer switch if the unit is to be used
as a standby power supply. Then continue with the steps described below:
1. Perform a manual start of the unit at least once to verify that the engine is operating correctly.
Note: The lights are automatically disconnected on startup. The main circuit breaker can be left on if no other loads
are connected, except for the lights. Any connected external loads must be disconnected by a transfer switch when
starting the unit.
2. If a check of the remove start circuit is desired:
a. Remove the wires from the remote start terminal block. Press the Auto button. The Auto LED with be lit.
b. Attach a jumper wire (minimum 16 gauge) across the two terminals on the remote start terminal block.
This applies a ground to the L401 controller to close the starting circuit contacts. The engine should
crank, start and run.
c. Remove the jumper wire form the remote start terminal block and the engine will stop.
d. Reconnect any necessary wires form the remote start switch (transfer switch) to the remote start terminal
block.
3. Confirm the unit is in Auto mode. The Auto LED should be lit.
4. Secure the unit by closing and locking all access doors.
5. The unit is now ready for remote starting.
27
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 Control Power switch to the OFF (O) position to reset the unit after you have
determined the cause of the shutdown.
Note: The unit will turn off the lights at the stop time, but the engine will continue to run for up to five minutes as a
cool down. If the stop button is pressed, the unit will immediately stop.
LIGHT OPERATION
The lights are turned on and off using the L401 controller. To view the mast and light screens, press both ↑ and ↓
buttons simultaneously, the navigation menu is then displayed. Once entered, cycle to the mast and light section
and enter.
WARNING
NEVER operate the lights without the protective lens cover, or with a lens cover that
is cracked or damaged. The bulbs in the light fixtures produce high temperatures and
operate under pressure. A broken or missing lens cover could cause the bulbs to
shatter, causing injury.
1. Once the engine is up to temperature and running smoothly, switch the main circuit breaker to the ON (I) position.
2. The lights will automatically turn on 15 seconds after the unit is started. If it is desired to turn the lights on or off,
cycle through the mast and light screens until you find the screen that selects the light (s) to be turned on or off.
To turn the light(s) on, press and hold the ↑ button until the timer bar finishes. To turn the light(s) off, press and
hold the ↓ button until the timer bar finishes. The lights can be turned on or off individually or all together.
Turn Lights On or Off Individually Turn Lights On or Off at Same Time
3. 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 10 minutes before they can be switched on again.
4. The light tower uses four 1000W 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.
00899
28
CAUTION
Bulbs become extremely hot when in use. Allow bulb fixture to cool 10-15 minutes before
handling or lowering the mast.
VOLTAGE REGULATION
Units are equipped with an electronic voltage regulator. The voltage regulator controls the output of the generator
by regulating the current into the exciter field. The regulator has three screwdriver adjustable potentiometers that
may be adjusted for voltage, stability and voltage roll-off (U/F). The voltage regulator is adjusted before shipment
from the factory. Contact Magnum Power Products LLC for additional information before attempting to adjust the
voltage regulator.
DERATING FOR ALTITUDE
All units are subject to derating for altitude and temperature; this will reduce the available power for operating tools
and accessories connected to the receptacles. Typical reductions in performance are 2-4% for every 1000 ft (305
m) of elevation and 1% per 10ºF (5.6ºC) increase in ambient air temperature over 72ºF (22ºC).
WET STACKING
The unit is powered by a diesel engine. Diesel engines are susceptible to wet stacking if lightly loaded. Wet stacking
occurs when an engine is run at less than 30% of its full load capacity, causing unburned fuel to accumulate in the
exhaust system. Wet stacking can be detected by continuous black exhaust when the unit is under a constant load.
It can also cause fouling of injectors and buildup on engine valves. Diesel engines operate properly when applied
loads are between 30% and 100% capacity. Appropriate generator sizing is determined by the anticipated load. If
the unit is in a wet stack condition, load the unit heavily for five hours or until the exhaust is clear.
RECEPTACLE PANEL
The receptacle panel is equipped with six receptacles for
running accessories or tools from the generator. Power is
supplied to the receptacles any time the engine is running
and the main circuit breaker is switched to the ON (I)
position. Each receptacle has an individual circuit breaker
which is located behind the receptacle panel. The breakers
are labeled with the corresponding amperage for the receptacle they protect. The standard receptacle panel is
equipped with two of each of the following receptacles:
1. 240V/30A twist-lock
2. 120V/20A GFCI
3. 240V/50A twist-lock
Should the main breaker trip, remove some of the load to the receptacles before turning them back on.
With all of the lights off, the full generator output may be used with the receptacles.
Note: To ensure proper grounding, anytime the generator is providing power to any equipment or load panels that
do not have a grounded plug, a ground wire MUST BE added between the equipment and the grounding stud on
the receptacle panel per the National Electrical Code (NEC), state and local regulations.
1
2
3
Breakers Located
Behind The Panel
00194
29
REMOTE START TERMINAL BLOCK
The remote start terminal block provides a connection for installation of a remote start
switch which will allow the unit to be started by a remote dry-contact closure switch.
For location of the remote start terminal block, refer to “Main Control Panel” on page 17.
Before entering Auto mode, verify that the contacts on any remote switch linked to the
unit are OPEN. If the contacts on a remote switch are closed, the engine will crank
and start when Auto mode is entered. Attach the switch leads to the two unused
terminals on the unit’s remote start terminal block. For additional information, refer to
“Auto (Remote) Starting of the Unit” on page 27.
Remote Start
Switch Terminals
00886
TRANSFER SWITCH
The generator neutral is bonded to ground when shipped from the factory. The bonding
plate will need to be removed when the generator is used as a standby power supply.
Installation should be in compliance with the National Electrical Code (NEC), state and local
regulations.
When the generator is used as a standby power supply, it must be equipped with a transfer switch which isolates it
from the utility’s distribution system. A transfer switch is designed to transfer electrical loads from the normal power
source (utility) to the emergency power source (generator) when normal voltage falls below a prescribed level. The
transfer switch automatically returns the load back to the normal source when power is restored back to operating
levels.
DANGER
FAILURE TO ISOLATE THE GENERATOR FROM THE NORMAL POWER UTILITY CAN
CAUSE POTENTIALLY LETHAL VOLTAGE TO BACKFEED INTO THE UTILITY LINES.
THIS MAY RESULT IN INJURY OR ELECTROCUTION OF UTILITY WORKERS NEARBY.
MAKE SURE THE GENERATOR IS ISOLATED BY A TRANSFER SWITCH FROM ANY
LOCAL UTILITY LINES. THIS ALSO APPLIES IF THE GENERATOR IS BEING USED
AS A BACKUP TO SOME OTHER TYPE OF POWER SUPPLY.
Installation of a transfer switch or other type of remote starting device is the responsibility of the generator user.
Installation of such devices must be performed by following all directions supplied by the manufacturer of the switch.
If attaching the generator to a power supply normally serviced by a utility company, notify the utility company and
check state and local regulations. Familiarize yourself with all instructions and warning labels supplied with the switch.
Incoming
Utility
Power
Utility
Meter
Emergency
Distribution Panel
(Generator Power)
Main
Distribution Panel
(Utility Power)
Transfer
Switch
WHITE = Incoming
Utility Power
GRAY = Normal Utility
Power Circuit
BLACK = Emergency
Generator Power Circuit
Power From
Generator
30
00206
WARNING
ONLY a licensed electrician should perform wiring or related connections to the
generator. Installation should be in compliance with the National Electrical Code
(NEC), state and local regulations. Failure to follow these procedures could result in
property damage, personal injury or death. Before any connections are attempted,
make sure the main circuit breaker and the Control Power switch are in the OFF (O)
position and that the negative (-) battery cable has been disconnected from the battery.
When using the generator as a standby or substitute power supply, make sure the output
voltage and phase rotation of the generator match those of the local power utility. Improper
voltage or phase rotation may cause equipment damage or malfunction.
AUTO EXERCISE TIMER
The L401 controller is capable of starting and stopping the unit automatically, based on a programmable schedule.
Units installed in a standby application should be exercised regularly to maintain operating condition and to ensure
responsiveness in an emergency situation. Use the following procedures to operate the unit in Auto mode:
Note: The controller MUST be in Auto mode to run at the programmed time. Use a trickle or solar battery charger
to prevent the controller from draining the battery while in Auto mode.
1. Push both the Stop/Reset (O) and Auto buttons simultaneously.
2. Push the ↑ button until the wrench ( ) icon is selected. Push the Auto button to select it and enter the parameters.
3. Adjust the parameter number to enable the desired event. When the correct parameter number is showing, press
the Auto button to enter it. Press the Manual/Start (I) button to change it to 1 to enable the event and press the
Auto button to save it.
Note: The ↑ and ↓ buttons will adjust the hundredths place of the parameter number and the Manual/Start (I) and
Stop/Reset (O) buttons will adjust the low digits. Up to eight events can be scheduled at a time.
4. Adjust the parameter number to adjust the time of the desired event and then press the Auto button to enter it.
Press the Manual/Start (I) and Stop/Reset (O) buttons to change the time. Holding down either button will change
the time faster. Press the Auto button to save the time.
5. Adjust the parameter number to adjust the day of the week and press the Auto button to enter it. Press the
Manual/Start (I) and Stop/Reset (O) button to change to the desired day and press the Auto button to save it.
Note: Only one day can be chosen per event if parameter 903 is “1” (monthly).
6. Adjust the parameter number to adjust duration of the timer and press the Auto button to enter it. Press the
Manual/Start (I) or Stop/Reset (O) buttons to change the duration and press the Auto button to save it.
Note: If any of the scheduled time slots are currently active, the controller will begin the starting sequence and start
the unit provided there are no shutdown conditions present.
The times for the scheduled timers/events are based on the internal clock for the controller. Use the corresponding
parameters to adjust to the correct time of the day and correct date.
31
This table lists the parameters needed to schedule an event and to adjust the clock within the controller.
Note: If parameter 902 is “0”, then the auto exercise timer is enabled and if it is “1”, then the autolight timer is enabled.
Parameter Description Details
Configuration Parameters - Scheduler
901 Enable Scheduler On (1), Off (0)
902 Schedule Run On or Off Load On (1), Off (0)
903 Schedule Period Weekly (0), Monthly (1)
904 Scheduler (1) Start Time 0:00:00
905 Scheduler (1) Start Day 0 (1=Monday)
906 Scheduler (1) Start Week 1,2,3,4
907 Scheduler (1) Duration 0:00:00
908 Scheduler (2) Start Time 0:00:00
909 Scheduler (2) Start Day 0 (1=Monday)
910 Scheduler (2) Start Week 1,2,3,4
911 Scheduler (2) Duration 0:00:00
912 Scheduler (3) Start Time 0:00:00
913 Scheduler (3) Start Day 0 (1=Monday)
914 Scheduler (3) Start Week 1,2,3,4
915 Scheduler (3) Duration 0:00:00
916 Scheduler (4) Start Time 0:00:00
917 Scheduler (4) Start Day 0 (1=Monday)
918 Scheduler (4) Start Week 1,2,3,4
919 Scheduler (4) Duration 0:00:00
920 Scheduler (5) Start Time 0:00:00
921 Scheduler (5) Start Day 0 (1=Monday)
922 Scheduler (5) Start Week 1,2,3,4
923 Scheduler (5) Duration 0:00:00
924 Scheduler (6) Start Time 0:00:00
925 Scheduler (6) Start Day 0 (1=Monday)
926 Scheduler (6) Start Week 1,2,3,4
927 Scheduler (6) Duration 0:00:00
928 Scheduler (7) Start Time 0:00:00
929 Scheduler (7) Start Day 0 (1=Monday)
930 Scheduler (7) Start Week 1,2,3,4
931 Scheduler (7) Duration 0:00:00
932 Scheduler (8) Start Time 0:00:00
933 Scheduler (8) Start Day 0 (1=Monday)
934 Scheduler (8) Start Week 1,2,3,4
935 Scheduler (8) Duration 0:00:00
Configuration Parameters - Time and Date
1001 Time of Day 0:00:00
1002 Day of Month 1-31
1003 Month of Year 1-12
1004 Year 0-99
32
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 hazards by accidentally turning off equipment that needs to be kept on
(pumps, compressors, lights, etc.).
1. Remove all loads from the receptacles.
2. Remove any hoses connected to the hose bibbs.
3. Switch the individual circuit breakers for each light to the OFF (O) position.
4. Switch the main circuit breaker to the OFF (O) position.
5. Press the Stop (O) button.
6. After the unit shuts down, move the Control Power switch to the OFF (O) position.
Note: For extended storage time, disconnect the battery. For extended storage requirements, refer to the engine
operator’s manual.
USING THE WATER SUPPLY
CAUTION
DO NOT use water in the supply tank for human consumption. The tank is made to store
water for washing or domestic purposes only. Drinking water from the tank could result in
immediate or long term harm.
The unit comes equipped with a 500 gallon (1,895 L) water tank and a manifold with four hose bibbs. This allows
the water tank to be connected to a trailer or RV for water to be used in non-potable applications. Two bibbs are for
gravity feed only and two bibbs are pressurized by the onboard pump; the pump only operates when the engine is
running.
Note: Even if the water being put into the tank is potable, it cannot be used for human consumption because the
storage tank is not of food grade material.
TO USE THE PRESSURIZED WATER SUPPLY BIBB(S):
1. Connect a hose from one of the pressure bibbs to the
end location (trailer, RV, etc.).
2. Start the engine on the unit.
3. Switch the main circuit breaker to the ON (I) position.
4. Open the pressure bibb(s).
5. Switch the pump on; it will stop automatically when
the water pressure reaches 35 psi (241 kPa).
TO USE THE GRAVITY WATER SUPPLY BIBB(S):
1. Connect a hose from one of the gravity bibbs to the
end location.
2. Open the gravity bibb(s).
Gravity
Bibbs
Pump
Switch
Pressure
Bibbs
00229
33
Drain the tank when the temperature is expected to drop below 32°F (0°C) or if the unit is
to be stored for a long period of time.
TO REFILL THE WATER TANK:
1. Close all hose bibbs.
2. Remove the tank cover; leave the smaller inspection cap in the center of the cover in place.
3. Fill the tank from a water source.
LOWERING THE MAST - MANUALLY
1. Shut down the lights and engine, refer to “Shutting Down the Unit” on page 32. Allow the lights to cool 10-15
minutes before lowering the mast.
2. Loosen the mast rotation knob. Rotate the mast until the white arrows are aligned and the metal stop tabs are
touching. Tighten the mast rotation knob.
3. Turn the upper mast winch handle counterclockwise to collapse the mast to its lowest position. Ensure the
electrical cord does not get caught in, or pinched 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 handle
of the lower mast winch counterclockwise until the mast rests in the transport cradle.
Note: If the mast lock bar does not pull free, activate the lower winch slightly 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 trailer is going to be moved, Magnum Power Products LLC strongly recommends the lights be removed
from the mast and stowed for transportation. Refer to “Removing the Lights for Transportation” on page 34.
LOWERING THE MAST - ELECTRIC WINCH OPTION
1. Shut down the lights and engine, refer to “Shutting Down the Unit” on page 32. Allow the lights to cool 10-15
minutes before lowering the mast.
2. Loosen the mast rotation knob. Rotate the mast until the white arrows are aligned and the metal stop tabs are
touching. Tighten the mast rotation knob.
3. Press and hold the upper winch control switch downward to collapse the mast to its lowest position. Ensure the
electrical cord does not get caught in, or pinched by, the mast while it is being lowered.
Note: Some electric winch models are equipped with an anti-backlash safety limit switch. This switch will disconnect
power to the winch if excess cable slack is detected, preventing accidental lowering of the mast.
34
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. Lower the mast
by holding the lower winch control switch to the right until the mast is resting in the transport cradle.
Note: If the mast lock bar does not pull free, activate the lower winch slightly 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 trailer is going to be moved, Magnum Power Products LLC strongly recommends that the lights be
removed from the mast and stowed for transportation. Refer to “Removing the Lights for Transportation” on page 34.
REMOVING THE LIGHTS FOR TRANSPORTATION
1. On units equipped with quick disconnect fittings for the lights, disconnect the power
cords from the junction box at the top of the mast. Replace the dust caps on the
junction box. On hard wired units, remove the junction box cover, located on the
top of the mast, and disconnect ONLY the mast light wires from the connectors.
To release the mast light wires from the connectors, flip the locking levers down
and pull out the appropriate wires.
2. Remove the lights by removing the wing nut that holds the light fixture bracket to
the cross tube. Attach the lights to the storage brackets (if equipped) located on
the mast tube on either side of the central lift point.
00232
TOWING THE UNIT
Once the engine is shut down and the mast and lights are properly stowed, follow these steps to prepare the unit
for towing.
1. Raise the four leveling jacks completely and release the locking pin to rotate them up into the travel position.
Make sure the locking pins snap into place.
2. 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. Raise the tongue jack completely.
Note: A film of grease on the coupler will extend coupler life and eliminate squeaking. Wipe the coupler clean and
apply fresh grease each time the unit is towed.
3. To ensure proper operation of the jacks, lube the grease fittings located on the leveling jacks. Refer to “Jack
Maintenance” on page 40. For maintenance interval information, refer to “Basic Maintenance Schedule - Isuzu
Engine” on page 37.
4. Connect any trailer wiring to the tow vehicle. Check for proper operation of the directional and brake lights.
5. Make sure the mast cradle locking pin is in place.
6. Make sure the doors are properly latched.
7. If the unit is going to be driven over rough ground, remove the bulbs from the light fixtures.
8. Check for proper inflation of the trailer tires. Refer to “Specifications” on page 10.
35
9. Check the wheel lugs. Tighten or replace any lugs that are loose or missing. If a
tire has been replaced or removed for axle service, tighten the lugs, in the order
shown, to the following specifications:
A. Start all lug nuts by hand.
B. First pass tighten to 20-25 ft-lbs (27-33 Nm).
C. Second pass tighten to 50-60 ft-lbs (67-81 Nm).
D. Third pass tighten to 90-120 ft-lbs (122-162 Nm).
1
4
3
2
5
Note: After the first road use, re-torque the lug nuts in sequence.
00204
10. Maximum recommended speed for highway towing is 45 mph (72 km/h). Recommended off-road towing speed
is not to exceed 10 mph (16 km/h) or less, depending on the terrain.
LIFTING THE UNIT
WARNING
WATER TANK MUST BE EMPTY BEFORE LIFTING THE UNIT. Only lift a combination
unit using the lower forklift pockets, do not use the center lift point or mast mounted
forklift pockets. Failure to comply may result in damage to equipment and/or serious
personal injury.
1. Make sure the equipment being used to lift the unit has
sufficient capacity. For approximate weights, refer to
“Specifications” on page 10.
2. Make sure the cradle locking pin is in place.
3. Always remain aware of people and objects around
the unit while moving.
4. Use the lower forklift pockets with care. Approach the
unit as perpendicular as possible to avoid any damage
to the unit. Make sure the mast winch handles or any
other obstructions are clear of the forklift tines before
lifting.
Do NOT Use To Lift
Use Lower Forklift Pockets To Lift
00908
GENERAL MAINTENANCE
Poorly maintained equipment can become a safety hazard. In order for the equipment to operate safely and properly
over a long period of time, periodic maintenance and occasional repairs are necessary. NEVER perform routine
service (oil/filter changes, cleaning, etc.) unless all electrical components are shut off. Before servicing the unit,
always follow the instructions listed below.
• Ensure the Control Power switch is turned to the OFF (O) position.
• Ensure the circuit breakers are open, in the OFF (O) position.
• Activate (push in) the emergency stop switch.
• 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 pressure hose or with any kind of power washer.
• Never wash the engine block or fuel tank with a power washer or steam cleaner. Water may enter the cabinet
and collect in the generator windings or other electrical parts, causing damage.
• If the unit is stored outside, check for water inside the cabinet and generator before each use. If wet, dry the
unit thoroughly before starting.
• Inspect condition of electrical cords. DO NOT use the unit if insulation is cut or worn through.
36
• Check that winch cables are in good condition
and are centered on each pulley. DO NOT use a
cable that is kinked or starting to unravel.
• Check that the safety pins for the mast lock rod
and mast lock bar are present and secured with
a chain. Check that the spring located in the mast
lock bar is not broken or missing. Check the
operation of the mast lock bar.
• Check the wheel lugs. Refer to “Towing the Unit”
on page 35.
• Check coolant levels. Refer to the engine oper-
ator’s manual when determining proper mixture.
○ Coolant is checked visually by inspecting the level in the coolant overflow jug near the radiator.
○ Normal operation is between the full and add markings on the overflow jug, this is known as normal range.
○ WHEN ENGINE IS STOPPED AND COMPLETELY COOL, coolant may be added directly to the jug.
• Check the oil levels. Refer to the engine operator’s manual when determining proper viscosity.
○ DO NOT start the unit if the engine oil level is below the add mark on the dipstick.
○ Normal operation is between the full and add markings on the dipstick.
○ Add oil only if oil level is below cross-hatch pattern on the dipstick. DO NOT OVERFILL crankcase.
• Check fuel level.
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.
PROPER MAST CABLE ROUTING
00131
BASIC MAINTENANCE SCHEDULE - ISUZU ENGINE
Refer to the original equipment manufacturer’s operating manual for a complete list of
maintenance requirements. Failure to comply with the procedures as described in the engine
operator’s manual will nullify the warranty, decrease performance and cause equipment
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.
Item Daily
Check Oil Level
Check Coolant Level
Check Fuel Level
Drain Fuel Filter
Check Tire Pressure
Check All Electrical Connections
Clean Battery
Check Fan Belt Tension (Replace If Necessary)
Inspect Radiator Fins For Debris, Clean As Required
Preheating Condition Check
Check Engine Starting Conditions And Noise Conditions
Check Exhaust Smoke Condition
Inspect Light Tower Winch For Proper Operation
Replace Engine Oil
Replace Fuel Filter Element
Clean Water Sedimenter Element
Electromagnetic Pump Filter Replacement or Cleaning
250
Hours
500
Hours
1000
Hours
37
Item Daily
Check Fan Belt Tension (Replace If Necessary)
Oil Filter Element Replacement
Replace Air Filter Element
Lubricate Leveling Jacks
Replace Heated Fuel Filter (If Equipped)
Inspect Engine Starting Battery
250
Hours
500
Hours
1000
Hours
RESETTING THE MAINTENANCE ALARMS
The L401 controller will display a warning message when the unit is due for maintenance or service. The maintenance
or service intervals are set at 250, 500, and 3000 hours of engine running time. Once the unit has been serviced,
the appropriate maintenance alarm reminder needs to be reset.
To remove the fault of latching alarms, press the Stop/Reset (O) button on the controller for 10 seconds on the desired
Maintenance Alarm Status page.
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 oil or grease.
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.
38
3. Do not get oil or grease on the friction discs.
Grease
Oil
Friction Discs
(No Grease/Oil)
WINCH USE, OPERATION & MAINTENANCE - ELECTRIC
• Keep 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 cable for visible damage every time 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 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.
• Periodically clean and grease brake assembly. This will ensure proper performance and extend the life of
the winch. If winch seems to labor or get excessively hot during the lowering of loads, the brake will need
to be serviced or replaced.
• Check motor brushes periodically and replace when necessary.
00244
Note: Only the motor brushes and brake assembly require periodic replacement.
PREVENTIVE MAINTENANCE SCHEDULE
Maintenance Activity
Check Fasteners
Check Electrical Connections
Clean And Grease Brake Assembly
Check Motor Brushes
Visually Check Winch And Control
MECHANICAL BRAKE
The mechanical brake generates heat when loads are lowered and the wire cable is powered out. Care must be
taken to avoid overheating the mechanical brake.
Whine or chatter associated with a new mechanical brake is normal and typically disappears with use.
Overheating the mechanical brake may result in permanent damage to, or failure of, the brake. Replace any damaged
brake components before resuming use of the winch.
After First
Operation
Before Each Use
Semi-Annually Or
After Each 25 Hours
Of Operation
39
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
standard grease gun on the lubrication point found on the side of the jack near the crank. Rotate the jack
handle to distribute the grease evenly.
• A lightweight oil must be applied to the handle unit at both sides of the tube.
• If equipped, the axle bolt and nut assembly of the caster wheel must also be lubricated with the same light
weight oil.
TOP-WIND MODELS
• Apply a lightweight oil to the screw stem.
Oil
Grease
Grease
Oil
Grease
Oil
Oil
Oil
00243
TRAILER WHEEL BEARINGS
The trailer axles are equipped with a grease zerk fitting to allow lubrication of the wheel bearings without the need
to disassemble the axle hub. To lubricate the axle bearings, remove the small rubber plug on the grease cap, attach
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 12,000 miles (19,312 km). More frequent lubrication may be required
under extremely dusty or damp operating conditions.
LOWER RADIATOR HOSE HEATER OPTION - USE AND MAINTENANCE
CAUTION
Improper use of the lower radiator hose heater could result in damage to the engine or
personal injury. Do not modify the location of the lower radiator hose heater.
The following points should be followed when operating a unit equipped with a lower radiator hose heater.
• Ensure the cooling system is full of the proper 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
amperage rating of 10A. Connect the cord to a properly grounded 120VAC, GFCI receptacle.
• Before starting the engine, unplug the extension cord from the power first, then unplug the heater cordset
from the extension cord.
40
TROUBLESHOOTING THE LIGHTS
DANGER
THIS UNIT USES HIGH VOLTAGE CIRCUITS CAPABLE OF CAUSING SERIOUS
INJURY OR DEATH. ONLY A QUALIFIED ELECTRICIAN SHOULD TROUBLESHOOT
OR REPAIR ELECTRICAL PROBLEMS OCCURRING IN THIS EQUIPMENT.
MAST LIGHTS ON BUT THE LIGHT OUTPUT IS LOW
1. Fixture and/or lens is dirty. Clean reflective surface inside fixture and both inside and outside surface of
glass lens. Use mild soap and water to clean lens. Other chemicals may have an adverse effect on the
glass.
2. Bulb worn due to normal use. Replace bulb.
3. Check the mast coil cord, mast junction box and mast light connections.
4. Generator output incorrect. Check the incoming voltage. Incoming voltage should be 120V +/- 5V. If the
voltage is incorrect, adjust the voltage regulator.
5. Low transformer output. The voltage from the transformer should read approximately 400VAC as the
light “strikes” (induces an arc), then drop and slowly rise back up to stabilize at 240-260VAC. On quick
disconnect models, measure across the junction box terminals when the light is unplugged. On hard
wired models, remove the mast junction box cover and insert the wire probes into the connector blocks
for the light and ground. If proper voltage is not achieved, perform capacitor check to determine if the
capacitor or coil needs to be replaced.
If problems persist, contact Magnum Power Products LLC Technical Service at 1-800-926-9768 for assistance.
TROUBLESHOOTING AUTOMATIC SHUTDOWN CONDITIONS
WARNING
Allow engine to cool before performing any troubleshooting procedures. Contacting
the engine when it is hot will cause severe personal injury.
LOW OIL PRESSURE SHUTDOWN
1. Check the level of the engine oil with the dipstick. The engine controller will shut the engine down when
the oil pressure is less than 15 psi (103 kPa). Add oil if required.
2. Visually inspect the engine for oil leaks.
3. If the oil level is good, restart the unit and verify the loss of oil pressure. Shut the engine down immediately
if the oil pressure value does not read 5 psi (34 kPa) within five seconds.
4. Check the oil pressure sender. To identify corrective action, refer to the troubleshooting section of the
engine operator’s manual provided with the unit.
HIGH COOLANT TEMPERATURE SHUTDOWN
1. Check the coolant level in the overflow jug.
2. Restart the engine and read the coolant temperature to verify a high coolant temperature shutdown.
Stop the engine immediately if the coolant temperature is 210°F (99°C) or more.
3. Allow the engine to cool. Add coolant to the overflow jug if it is low and then check the level of coolant
in the radiator. To access the radiator cap, you must remove the access panel from the top of the enclosure
directly above the radiator. Add coolant until it is 3/4 in. (1.9 cm) below the filler neck. Secure the radiator
cap back into its original position.
4. Check the radiator shroud and ducting for blockage and remove any foreign matter.
5. Inspect coolant hoses, engine block and water pump for visible leaks.
6. Check the tension of the serpentine drive belt for the water pump.
7. If no other problems are found, remove the load on the generator and restart the engine. Check the
coolant temperature and shut the engine down immediately if it starts to overheat. Refer to the engine
operator’s manual for additional information on engine overheating.
41
MAST LIGHT CONNECTIONS
MAST JUNCTION BOX WIRING
4-LIGHT
MAST LIGHT CONNECTIONS
4-LIGHT
21
2
1
43
4
3
00175
42
AC WIRING DIAGRAM
GN
3
WT
WT
1
WT
GN
BK
BK
GN
GN
BK
BK
BL
RD
BK
GN
YL OR ORN
WT/BK OR BN
L1
L2
CAP 2
CAP 1
4
2
MAIN
WT
WT
MAST CABLE
BREAKER
MAIN
1
2
3
4
1
2
3
4
TO PUMP CIRCUIT BREAKER
BK
BK
CIRCUIT
BREAKER
TO RECEPTACLES
BK
BK
L1
F+
RD
RDBKRD
RD
GEN
BK
GN
3
BK
2
1
RD
GY
GN
BL
BK
RD
GY
BL
BK
RD
WT
TB1
BK1
BK2
BK3
BK4
RD4
RD3
RD2
RD1
BL2
BL1
BK2
RD1
RD2
GY1
1
2
TB2
BL
RD
YL OR ORN
SEE DC DIAGRAM
RD
100A
WT
L2
N
GN
F-
BN
BK
BK1
GY2
9876543
11
10
12
13
14
YLRDBL
BK
RELAY
COIL
TO CNTRL 9
YL
RELAY
COIL
TO CNTRL 8
RD
RELAY
COIL
TO CNTRL 7
BL
RELAY
COIL
TO CNTRL 6
BK
60HZ
50HZ
4
6
SE350
7
F-
4 AMP FUSE
F+
ON REGULATOR
3
VOLTAGE REGULATOR
BK
4
YL 14AWG
COIL
YL 14AWG
BK/WT
BAR
3
TO GND
RD 14AWG
COIL
2
COIL
1
COIL
BK/WT
COM NO COM NO COM NO
BK/WT
COM NO
BK/WT
RD 14AWG
BAR
TO GND
BL 14AWG
BL 14AWG
BAR
TO GND
BK 14AWG
BK 14AWG
BAR
TO GND
3
BK
2
1
RD
3
BK
2
1
RD
3
BK
2
1
RD
GN1
GN2
GN3
WT/BK OR BN
1
2345678
WT
GN/YL
TO RECEPTACLES
TRANSFORMERS
GN
GN
12 43
GN4
9
10
WT
WT
GN
BK
TO CNTRL 24
BK
PUMP
SWITCH
10A FUSE
TO MAIN CIRCUIT BREAKER L1
CIRCUIT BREAKERS
YL
RD
15A 15A
BL
BK
15A 15A
RD 14AWG
RD 14AWG
BK 14AWG
BK 14AWG
1234
90567_B_09.09.14
TRANSFER PUMP
43
AC WIRING DIAGRAM - RECEPTACLE PANEL
BREAKER
TO MAIN
BLK
RED
BLK
RED
BLK
RED
BLK
RED
RED
50 AMP
CIRCUIT
BREAKER
50 AMP
CIRCUIT
30 AMP
CIRCUIT
BREAKER BREAKER
BLK
RED
BLK
RED
BLK
RED
RED
50 AMP
240 VOLT
50 AMP
240 VOLT
30 AMP
240 VOLT
TWIST-LOCK
TWIST-LOCK
RECEPTACLE RECEPTACLE
TWIST-LOCK
RECEPTACLE
WHT
WHT
GRN GRN
WHT
GRN
WHT
TO NEUTRAL
TO GROUND
WHT
GRN
30 AMP
CIRCUIT
BREAKER
BLKBLK
20 AMP
CIRCUIT
BREAKER
RED
20 AMP
CIRCUIT
RED
BREAKER
30 AMP
120 VOLT
G.F.I
20 AMP
G.F.I
20 AMP
RV RECPTACLE
WHT
RECEPTACLE
GRN
WHT
GRN
GRN
44
(2x5-20R, 1xTT-30, 1xL14-30R, 2x14-50)
RECEPTACLE
90317_ORG_07.06.11
AC WIRING DIAGRAM - RECEPTACLE PANEL OPTIONS (1 OF 2)
TO GROUND
TO NEUTRAL
TO MAIN
BREAKER
20 AMP
G.F.I
OUTLET
20 AMP
G.F.I
OUTLET
20 AMP
CIRCUIT
BREAKER
20 AMP
CIRCUIT
BREAKER
GRN
WHT
RED
RED
20 AMP
G.F.I
OUTLET
GRN
20 AMP
CIRCUIT
BREAKER
BLKBLK
WHT
GRN
WHT
30 AMP
CIRCUIT
BREAKER
240 VOLT
30 AMP
TWIST LOCK
RECEPTACLE
GRN
RED
BLK
RED
BLK
RED
BLK
WHT
30 AMP
CIRCUIT
BREAKER
240 VOLT
30 AMP
TWIST LOCK
RECEPTACLE
GRN
RED
BLK
RED
BLK
WHT
RED
50 AMP
CIRCUIT
BREAKER
RED
240 VOLT
50 AMP
TWIST LOCK
RECEPTACLE
GRN GRN
WHT
BLK
BLK
50 AMP
CIRCUIT
BREAKER
240 VOLT
50 AMP
TWIST LOCK
RECEPTACLE
RED
RED
WHT
Receptacle Panel (2x5-20R, 2xL6-30R, 2xL14-50) 90315_ORG_10.14.11
TO GROUND
TO NEUTRAL
GRN
WHT
RED
RED
20 AMP
G.F.I
OUTLET
GRN
20 AMP
CIRCUIT
BREAKER
BLKBLK
240 VOLT
WHT
GRN
WHT
TWIST LOCK
RECEPTACLE
30 AMP
CIRCUIT
BREAKER
30 AMP
TO MAIN
BREAKER
RED
BLK
RED
BLK
RED
BLK
TWIST LOCK
GRN
RECEPTACLE
WHT
CIRCUIT
BREAKER
240 VOLT
30 AMP
30 AMP
RED
BLK
RED
BLK
TWIST LOCK
GRN
RECEPTACLE
WHT
RED
30 AMP
CIRCUIT
BREAKER
RED
240 VOLT
30 AMP
GRN GRN
WHT
BLK
BLK
TWIST LOCK
RECEPTACLE
CIRCUIT
BREAKER
240 VOLT
50 AMP
RED
50 AMP
RED
WHT
BLK
BLK
BLK
BLK
20 AMP
G.F.I
OUTLET
20 AMP
CIRCUIT
BREAKER
Receptacle Panel (2x5-20R, 3xL6-30R, 1xL14-50)
TO GROUND
TO NEUTRAL
GRN
WHT
RED
RED
20 AMP
G.F.I
OUTLET
GRN
20 AMP
CIRCUIT
BREAKER
BLKBLK
WHT
GRN
WHT
TWIST LOCK
RECEPTACLE
20 AMP
CIRCUIT
BREAKER
240 VOLT
20 AMP
TO MAIN
BREAKER
RED
BLK
RED
BLK
RED
BLK
TWIST LOCK
GRN
RECEPTACLE
WHT
CIRCUIT
BREAKER
240 VOLT
20 AMP
RED
20 AMP
RED
GRN
WHT
BLK
20 AMP
CIRCUIT
BREAKER
BLK
240 VOLT
20 AMP
TWIST LOCK
RECEPTACLE
GRN GRN
RED
RED
WHT
90318_ORG_07.06.11
BLK
50 AMP
CIRCUIT
BREAKER
BLK
240 VOLT
50 AMP
TWIST-LOCK
RECEPTACLE
Receptacle Panel (2x5-20R, 3xL6-20R, 1x50A) 90319_ORG_07.06.11
RED
BLK
BLK
RED
WHT
45
AC WIRING DIAGRAM - RECEPTACLE PANEL OPTIONS (2 OF 2)
TO GROUND
TO NEUTRAL
TO MAIN
BREAKER
20 AMP
G.F.I
OUTLET
20 AMP
G.F.I
OUTLET
20 AMP
CIRCUIT
BREAKER
20 AMP
CIRCUIT
BREAKER
GRN
WHT
RED
RED
20 AMP
G.F.I
OUTLET
GRN
20 AMP
CIRCUIT
BREAKER
BLKBLK
WHT
GRN
WHT
30 AMP
CIRCUIT
BREAKER
240 VOLT
30 AMP
TWIST LOCK
RECEPTACLE
GRN
RED
BLK
RED
BLK
30 AMP
CIRCUIT
BREAKER
RED
BLK
240 VOLT
30 AMP
TWIST LOCK
RECEPTACLE
GRN
WHT
Receptacle Panel (2x5-20R, 3xL14-30R, 1x50A)
TO GROUND
TO NEUTRAL
GRN
WHT
RED
RED
20 AMP
G.F.I
OUTLET
GRN
20 AMP
CIRCUIT
BREAKER
BLKBLK
WHT
GRN
WHT
30 AMP
CIRCUIT
BREAKER
240 VOLT
30 AMP
TWIST-LOCK
RECEPTACLE
GRN
RED
RED
RED
WHT
TO MAIN
BREAKER
BLK
BLK
BLK
30 AMP
CIRCUIT
BREAKER
240 VOLT
30 AMP
TWIST-LOCK
RECEPTACLE
GRN
RED
BLK
RED
BLK
WHT
RED
BLK
BLK
RED
WHT
RED
30 AMP
CIRCUIT
BREAKER
RED
240 VOLT
30 AMP
TWIST LOCK
RECEPTACLE
GRN GRN
WHT
RED
30 AMP
CIRCUIT
BREAKER
RED
240 VOLT
30 AMP
TWIST-LOCK
RECEPTACLE
GRN GRN
WHT
BLK
50 AMP
CIRCUIT
BREAKER
BLK
240 VOLT
50 AMP
TWIST-LOCK
RECEPTACLE
90320_ORG_07.06.11
BLK
30 AMP
CIRCUIT
BREAKER
BLK
240 VOLT
30 AMP
TWIST-LOCK
RECEPTACLE
RED
BLK
BLK
RED
WHT
RED
BLK
BLK
RED
WHT
46
20 AMP
G.F.I
OUTLET
20 AMP
CIRCUIT
BREAKER
Receptacle Panel (2x5-20R, 4xL14-30R)
TO GROUND
TO NEUTRAL
GRN
WHT
RED
RED
20 AMP
G.F.I
OUTLET
GRN
20 AMP
CIRCUIT
BREAKER
BLKBLK
WHT
GRN
WHT
RV RECPTACLE
30 AMP
CIRCUIT
BREAKER
120 VOLT
30 AMP
GRN
TO MAIN
BREAKER
RED
BLK
RED
30 AMP
CIRCUIT
BREAKER BREAKER
RED
120 VOLT
30 AMP
RV RECEPTACLE
GRN
WHT
BLK
50 AMP
CIRCUIT
BLK
240 VOLT
50 AMP
TWIST-LOCK
RECEPTACLE RECEPTACLE
GRN GRN
WHT
RED
BLK
BLK
RED
WHT
90321_ORG_07.06.11
50 AMP
CIRCUIT
BREAKER
240 VOLT
50 AMP
TWIST-LOCK
Receptacle Panel (2x5-20R, 2xTT-30, 2x14-50) 90355_ORG_07.06.11
RED
BLK
BLK
RED
WHT
DC WIRING DIAGRAM
L
E-STOP
SWITCH
RD/VI
FUEL
WT/VI
LEVE
BK/WT
TO GND
BAR
2
NC
1
VI/YL
E-STOP
4
3
SWITCH
LOW
NO
BK/WT
TO GND
COOLANT
A
B
GY/BK
BK/WT
BAR
BAR
TO GND
STARTER
RD
ALT
12 V
-+
BATTERY
BLOCK
TO ENGINE
RD/YL
RD
24
SPLICE
VI/YL
4
RELAY
COIL
COIL
YL
BK/WT
3
RELAY
COIL
COIL
RD
BK/WT
2
CONTACTS
1
GY/OR
RELAY
COM NO COM NO COM NO
COIL
COIL
BL
BK/WT
1
RELAY
COM NO
COIL
COIL
BK
BK/WT
GY/BK
GY
RD
10A
L1
MAIN
L2
TO TB1-6L
WT
RD
BK
SEE AC DIAGRAM
BREAKER
BK
CT-1
WT
RD/WT
BAR
TO GND
BAR
TO GND
BK
CT-3
WT
BAR
TO GND
BK/WT
POWER
SWITCH
CONTROL
BAR
TO GND
RD/BK
BK/WT
RD/VI
RD/YL
BKBLRD
REMOTE START
2
TB3
BK/WT
BAR
TO GND
YL
TO CB4
YL 14AWG
TO TB2-11
YL 14AWG
BAR
TO GND
TO CB3
RD 14AWG
TO TB2-12
RD 14AWG
BAR
TO GND
TO CB2
BL 14AWG
TO TB2-13
BL 14AWG
BAR
TO GND
TO CB1
BK 14AWG
TO TB2-14
BK 14AWG
BAR
TO GND
SEE AC DIAGRAM
BK
WT/VI
GY
TO GND
VI/YL
VI/YL
BAR
BK
GY
SHIELD
IGNITION
3
IS REG
20
BK/WT
1
13
31 PIN ISUZU HARNESS
CAN HI
CAN LO
98
CUT BACK AND TAPE
SHIELD NOT CONNECTED
GLOW LAMP
21
PIN
LOCATION
UPPER
DSEL401MKII
PLUG LOCATION
4 POS PLUG (GEN VOLTAGE)
PHASE L1 VOLTAGE
222324
PHASE L2 VOLTAGE
PHASE L3 VOLTAGE
NEUTRAL
29
272625
PIN
LOCATION
UPPER
5 POS PLUG (GEN CURRENT)
PLUG LOCATION
PHASE L3 CURRENT
PHASE L2 CURRENT
PHASE L1 CURRENT
PHASE GND
1
PIN
LOCATION
9 POS PLUG
LOWER
PLUG LOCATION
POWER - DC
2
4
3
POWER + DC
START
FUEL
6
8
9
7
5
OUTPUT C
OUTPUT F
CHARGE ALT
OUTPUT D
OUTPUT E
PIN
PLUG LOCATION
6 POS PLUG (BINARY INPUTS)
30
LOCATION
LOWER
INPUT A
3132333435
INPUT B
INPUT E
INPUT C
INPUT D
INPUT F
SWITCH INPUTS TO GND
PIN
LOCATION
11 POS PLUG
LOWER
PLUG LOCATION
10
OUTPUT G
11
12
OUTPUT I
OUTPUT H
15
16
14
13
ANALOG INPUT A
OUTPUT J
ANALOG IN COM
ANALOG INPUT B
171819
CAN H
ANALOG INPUT C
20
CAN L
CAN SCREEN
90545_ORG_07.02.14
47
DC WIRING DIAGRAM - ELECTRIC WINCH OPTION
YL
WINCH 2
BL
YL
BLK
RED
RED
WHT
UP
DOWN
SWITCH 2SWITCH 1
BLK
CONTACTOR 2
87
RELAY 2
PROX. AUX
YL/WT
8586
BRN
BLK
87A
30
BLK
BLU
BLK
PROX. SWITCH 2
BRN
BLK
WINCH 1
BL
DOWN
RED
RED
WHT
UP
87
RELAY 1
PROX. AUX
86 85
BRN
BLK
87A
VI/YL
RED
30
RED
BLU
BLK
BRN
-+
12 V
BATTERY
PROX. SWITCH 1
90463_ORG_07.26.13
48
DC WIRING DIAGRAM - INTERIOR LIGHT OPTION
CONNECT TO RED WIRE
10A CIRCUIT BREAKER
65002
FUSE
10A
LIGHT
DC WIRING DIAGRAM - BATTERY DISCONNECT OPTION
BATTERY
DISCONNECT
90574_ORG_09.12.14
+
-
12 V
BATTERY
DC WIRING DIAGRAM - BATTERY CHARGER OPTION
BR
BL
GR/YL
90575_ORG_09.12.14
12 VOLT 2 AMP CHARGER
RD
BK
68118_A_09.12.14
49
TRAILER LIGHTS WIRING DIAGRAM
AMBER
MARKER
LAMP
MARKER
LAMP
RED
RIGHT
TAIL/TURN
LAMP
BK
WT
BN
YL
PLUG
GN
TRAILER
BK
SPLICE
SPLICE
WT
BN
BK
SPADE
BK
SPADE
WT
RING
RD
SPLICE
GN
BK
WT
SPLICE
SPLICE
BK
BK
LAMP
AMBER
MARKER
BN
WT
BN
SPADE
BK
RED
BN
WT
SPADE
BK
LAMP
MARKER
YL
SPADE
RDWTBK
LEFT
TAIL/TURN
LAMP
BN
WT
SPADE
SPADE
BK
LICENSE
WT
90341_B_12.20.13
LAMP
PLATE
50
SERVICE LOG
OIL GRADE AND TYPE: ____________________________BRAND:___________________________________
COOLANT MIXTURE: ______________________________ BRAND:___________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
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__________________________________________________________________________________________
__________________________________________________________________________________________
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51
REV: ORG
PART NO: 37102
09.12.14
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