Magnum MLT 4250 User Manual

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Page 1

MLT 4250

OPERATING/PARTS MANUAL

Page 2

INTRODUCTION

This manual provides information and procedures to safely operate and maintain the light tower and generator . For your own safety and protection from physical injury , carefully read, understand, and observe the safety instructions described in this manual. The information contained in this manual was based on machines in production at the

time of publication. Magnum Products LLC reserves the right to change any portion of this information without notice.

DO NOT MODIFY or use this equipment for any application other than which it was designed for .

Magnum Products LLC recommends that a trained and licensed professional perform all electrical wiring and testing functions. Any wiring should be in compliance with the United S tates National Electric Code (NEC), st ate and local codes and Occupational Safety and Health Association (OSHA) guidelines.

Keep a copy of this manual with the unit at all times. Additional copies are available from Magnum Products LLC, or can be found at www.m-p-llc.com. An engine operators manual was also supplied with the unit at the time of shipment from the factory . The manual provides detailed operation and maintenance procedures for the engine. Additional copies of the engine operators manual are available from the engine manufacturer.

MAGNUM 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.m-p-llc.com

For technical or parts QUESTIONS, please contact Magnum Products’ Customer Support or

Technical Support team at 920-361-4442. Please have your serial number available.

T o ORDER SER VICE PARTS, please contact the dealer from which your purchased the unit,

or call Magnum Products 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:

Diesel engine exhaust and some of its constituents are known to the state

of California to cause cancer, birth defects and other reproductive harm.

WARNING

CALIFORNIA PROPOSITION 65 W ARNING:

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TABLE OF CONTENTS

INTRODUCTION .................................................................................................................2

T ABLE OF CONTENTS ......................................................................................................3

SAFETY NOTES................................................................................................................4

OPERA TING SAFETY........................................................................................................4

ENGINE SAFETY ..............................................................................................................5

SERVICE SAFETY ............................................................................................................5

TOWING SAFETY..............................................................................................................6

REPORTING TRAILER SAFETY DEFECTS .......................................................................6

UNIT SERIAL NUMBER LOCA TIONS.................................................................................6

SAFETY SYMBOL SUMMARY..........................................................................................7

SPECIFICA TIONS ........................................................................................................ 8 - 9

EXTERIOR LOCA TIONS ...................................................................................................10

MAIN CONTROL P ANEL COMPONENTS ........................................................................11

MAGNUM DIGIT AL CONTROLLER (MDC)................................................................ 12 - 13

GENERA TOR MONITORING ............................................................................................13

ENGINE MONITORING ............................................................................................ 14 - 15

FINE VOL TAGE ADJUSTMENT ....................................................................................... 15

MDC CONTROLLER INFORMA TION DISPLAYS, FUNCTIONS AND RESET....................16

MDC CONTROLLER - GENERA TOR OPERA TIONAL ST A TUS.........................................16

MDC CONTROLLER - ALARM MANAGEMENT ...............................................................16

MDC CONTROLLER LIST OF POSSIBLE ALARMS WITH DESCRIPTIONS..............17 - 18

MDC CONTROLLER - HISTORY ......................................................................................18

ADJUSTING THE DISPLAY BACKLIGHTING ....................................................................19

RESETTING THE “TIME TO SERVICE” REMINDER.........................................................19

GENERAT OR OUTPUT CONNECTION LUGS ..................................................................20

VOL TAGE SELECT OR SWITCH ...................................................................................... 21

AUXILIARY OUTLETS ......................................................................................................22

VOL TAGE REGULA TION..................................................................................................22

EMERGENCY STOP SWITCH ........................................................................................ 22

MAIN CIRCUIT BREAKER................................................................................................23

REMOTE ST ART TERMINAL BLOCK...............................................................................23

TRANSFER SWITCH ................................................................................................23 - 24

LIGHT TOWER SET-UP ...................................................................................................25

RAISING THE TOWER.....................................................................................................26

RAISING THE TOWER WITH OPTIONAL ELECTRIC WINCH...........................................27

LIGHT TOWER ST ART UP ...............................................................................................28

PRE-ST ART CHECKLIST .................................................................................................28

MANUAL ST ARTING OF THE GENERA T OR .............................................................28 - 30

AUTO (REMOTE) ST ARTING OF THE GENERA TOR .......................................................30

LIGHT OPERA TION..........................................................................................................31

SHUTTING DOWN THE GENERA TOR .............................................................................31

LOWERING THE TOWER ................................................................................................32

LOWERING THE TOWER WITH OPTIONAL ELECTRIC WINCH...................................... 32

REMOVING THE LIGHTS FOR TRANSPOR TA TION.........................................................33

TOWING THE TRAILER ...................................................................................................33

TRAILER WHEEL BEARINGS .........................................................................................33

LIFTING THE TRAILER..................................................................................................... 34

GENERAL MAINTENANCE..............................................................................................34

ENGINE MAINTENANCE .................................................................................................35

OPTIONAL LOWER RADIA TOR HOSE HEA TER USE AND MAINTENANCE ...................35

DERA TING FOR AL TITUDE ..............................................................................................36

TROUBLESHOOTING SHUTDOWN CONDITIONS ...........................................................36

TROUBLESHOOTING THE LIGHTS .................................................................................37

UNIT DECALS...........................................................................................................38 - 41

MANUAL WINCH MAST ASSEMBL Y........................................................................42 - 43

ELECTRIC WINCH MAST ASSEMBLY...................................................................... 44 - 45

FRAME AND COMPONENTS ...................................................................................46 - 48

GENERA TOR ASSEMBLY ...............................................................................................49

MAST JUNCTION BOX ASSEMBL Y - HARD WIRED LIGHTS...........................................50

MAST JUNCTION BOX ASSEMBL Y - QUICK DISCONNECT LIGHTS...............................51

ENCLOSURE ASSEMBL Y ........................................................................................52 - 53

AUXILIARY OUTLET P ANEL ASSEMBL Y..................................................................54 - 55

AUXILIARY OUTLET P ANEL OPTIONS.....................................................................56 - 57

LIGHT ASSEMBL Y ....................................................................................................58 - 59

ENGINE COOLING ASSEMBL Y................................................................................60 - 61

ENGINE ASSEMBL Y ................................................................................................ 62 - 63

CONTROL P ANEL ASSEMBL Y.................................................................................64 - 65

CONTROL BOX ASSEMBL Y .....................................................................................66 - 67

LUG DOOR ASSEMBL Y ..................................................................................................68

WIRING DIAGRAMS .................................................................................................69 - 75

Page

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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, may result in minor or moderate injury.

DANGER

INDICATES A HAZARDOUS SITUATION WHICH, IF NOT AVOIDED,

WILL RESULT IN DEATH OR SERIOUS INJURY.

WARNING

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury.

CAUTION

NOTICE

Indicates a hazardous situation which, if not avoided,

may 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 light tower be sure you read and understand all of the instructions! 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 light tower. The following points should be practiced at all times:

• The area immediately surrounding the light tower should be dry, clean, and free of debris.

• Position and operate the light tower on a firm, level surface.

• NEVER start a unit in need of repair.

• Lower tower when not in use, or if high winds or electrical storms are expected in the area.

• Make certain light tower is well grounded and securely fastened to a good earthen ground.

• The tower extends up to 30 ft. (9m). Make sure area above trailer is open and clear of overhead wires

and obstructions.

• Bulbs become extremely hot in use! Allow bulb and light fixture to cool 10-15 minutes before handling.

• Keep area behind trailer clear of people while raising and lowering mast!

• NEVER raise, lower or turn mast while unit is operating!

• Trailer must be leveled and outriggers extended before raising tower. Outriggers must remain ex-

tended while tower is up.

• If for any reason any part of mast hangs up or winch cable develops slack while raising or lowering tower, STOP immediately! Contact an authorized service representative.

• NEVER remove safety pin or pull mast locking pin while tower is up!

• NEVER use tower if insulation on electrical cord is cut or worn through.

• NEVER operate lights without protective lens cover in place or with a lens cover that is cracked or

damaged!

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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. Also read and follow all safety warnings described in the Engine Operator's Manual. A copy of this manual was supplied with 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 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 DBA 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. Sp arking occurs.

5. Engine misfires or there is excessive engine/generator vibration.

6. Operating on a combustible surface.

7. Protective covers are loose or missing.

8. If the ambient air temperature is above 1 10° F .

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 light tower, make sure the engine start switch is turned to OFF, circuit breakers are

open (off) 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 light tower. 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 main circuit breaker before disconnecting battery cables.

• Keep hands, feet, and loose clothing away from moving parts on generator and engine.

• 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 equipment safely. Always remain aware of the position of other people around you when lifting the equipment.

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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. Also, 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.

• Inspect the hitch and coupling for wear or damage. DO NOT tow trailer using defective parts!

• 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 that none are missing.

• Maximum recommended speed for highway towing is 45 m.p.h. Recommended off-road towing speed

is not to exceed 10 m.p.h. or less depending on terrain.

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.

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 trailer is towed.

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 Traf fic Safety Administration (NHTSA) in addition to notifying Magnum Product s 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 individual problem between you, your dealer, or Magnum Product s LLC.

T o contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-888-327-4236 or by fax at: (202)-366-

7882. Additional contact information can be found at: www .nhtsa.dot.gov .

UNIT SERIAL NUMBER LOCATIONS

Refer to the locations illustrated below to find the unit ID tag, and trailer ID tag on your unit. Important information, such as the unit serial number, model number and Vehicle Identification Number (V.I.N.) for your trailer 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 technical service information, you may be asked to specify this information.

V.I.N. Tag

MANUFACTURED BY/FABRIQUE PAR:

GVWR/PNBV:

GAWR/PNBE TIRE/PNEU RIM/JANTE

THIS VIEHICLE CONFORS TO ALL APPLICABLE STANDARDS PRESCRIBED UNDER THE CANADIAN MOTOR VIEHICLE SAFETY REGULATIONS IN ECCEFT ON THE DATE OF MANUFACTURE. / CE VEHICULE EST CONFORME A TOUTES LES NORMES QUI LUI SONT APPLICABLES EN VERTU DU REGLEMENT SUR LA VEHICULES DES AUTOMOBILES DU CANADA EN VIGUEUR A LA DATE SA FABRICATION.

THIS VIEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL MOTOR VEHICLE SAFETY STANDARDS (FMVSS) IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE.

V.I.N./N.I.V.: TYPE/TYPE DE VEHICULE:

DATE OF MFG: COLD INFL. PRESS./PRESS.

DE GONF A FROID

KPA(PSI/LPC)

SGL/DUAL

Located on inside

MADE IN USA

PRODUCTS LLC

215 Power Drive Berlin, WI 54923 1-800-926-9768

Model

Serial Number

Mfg. Code

lbs

rpm hz amb. temp.

RATING: CONT. STAND BY

1 Phase

3 Phase

KVA

FOR ELECTRICAL EQUIPMENT ONLY.

POUR MATERIAL

LR 114630-1

ELECTRIQUE SEULEMENT.

Unit ID Tag

of panel.

MADE IN USA

PRODUCTS LLC

215 Power Drive Berlin, WI 54923 1-800-926-9768

Model

Serial Number

Mfg. Code

lbs

rpm hz amb. temp.

RATING: CONT. STAND BY

1 Phase

3 Phase

KVA

FOR ELECTRICAL EQUIPMENT ONLY.

POUR MATERIAL

LR 114630-1

ELECTRIQUE SEULEMENT.

MANUFACTURED BY/FABRIQUE PAR:

GVWR/PNBV:

GAWR/PNBE TIRE/PNEU RIM/JANTE

THIS VIEHICLE CONFORS TO ALL APPLICABLE STANDARDS PRESCRIBED UNDER THE CANADIAN MOTOR VIEHICLE SAFETY REGULATIONS

IN ECCEFT ON THE DATE OF MANUFACTURE. / CE VEHICULE EST CONFORME A TOUTES LES NORMES QUI LUI SONT APPLICABLES EN

VERTU DU REGLEMENT SUR LA VEHICULES DES AUTOMOBILES DU CANADA EN VIGUEUR A LA DATE SA FABRICATION. THIS VIEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL MOTOR VEHICLE SAFETY STANDARDS (FMVSS) IN EFFECT ON THE DATE OF

MANUFACTURE SHOWN ABOVE.

V.I.N./N.I.V.: TYPE/TYPE DE VEHICULE:

DATE OF MFG: COLD INFL. PRESS./PRESS. DE GONF A FROID KPA(PSI/LPC)

SGL/DUAL

Page 7

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 beginning of the parts section of this 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 personal injury hazards.

Hot surface(s) nearby.

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.

Ultraviolet radiation hazard; Operate only with lens intact.

Asphyxiation hazard; Operate in well ventilated area.

Dangerous voltage may be present.

Anchor/tie down point.

Forklift here only.

Use clean diesel fuel only.

Burn/scald hazard; pressurized steam.

Stop engine before fueling.

Fire/explosion hazard; Keep open flames away from unit.

Lift here only.

Read and understand the supplied operator’s manual before operating unit.

Unit electrical ground.

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SPECIFICATIONS

Read this manual carefully before attempting to use this light tower. The potential for property damage, personal injury or death exists if this equipment is misused or installed incorrectly. Read all of the manuals included with this unit. Each manual details specific information regarding items such as set up, use and service requirements. Specifications are subject to change without notice.

MAGNUM MODEL MLT 4250

Engine

Make/Brand ........................................................ Isuzu

Model.................................................................. 4LE1-NYGV-01

Type.................................................................... Diesel, liquid cooled, 4-stroke

Horsepower - prime hp (kW) ............................... 31.5 (23.5)

Horsepower - standby hp (kW) ........................... 34.5 (25.7)

Operating Speed rpm ......................................... 1800

Displacement in3 (L) ........................................... 134.25 (2.20)

Cylinders - qty .................................................... 4

Fuel Consumption - 100% prime gph (Lph) ....... 1.80 (6.81)

Battery Type - Group Number ............................. 2 4

Battery Voltage (Quantity per Unit) ..................... 12V (1)

Battery Rating..................................................... 720 CCA

Generator

Make/Brand ........................................................ Marathon Electric

Model.................................................................. 282NSL1505

Type, Insulation ................................................... Brushless, H

Generator Set (Engine/Generator)

3Ø - Standby kW (kV A) ...................................... 20 (25)

Amps - 3Ø St andby - 480 (208V) A..................... 30 (69)

3Ø - Prime kW (kV A).......................................... 18 (23)

Amps - 3Ø Prime - 480 (208V) A ........................ 28 (64)

1Ø - Standby - kW (kVA) .................................... 16.0 (16.0)

Amps - 1Ø St andby - 240V A.............................. 67

1Ø - Prime - kW (kV A)........................................ 15.0 (15.0)

Amps - 1Ø Prime - 240V A ................................. 63

Frequency Hz ..................................................... 60

Power Factor ...................................................... 1 (1Ø), 0.8 (3Ø)

Dimensions

Length w/ mast stowed in (m) ............................ 170 (4.32)

Width in (m) ....................................................... 63 (1.60)

Width w/ outriggers extended in (m) ................... 140 (3.56)

Height w/ mast stowed in (m)............................. 70 (1.78)

Maximum height of tower ft (m) .......................... 30 (9.14)

Weights

Dry Weight lbs (kg)............................................. 2158 (979)

Operating Weight lbs (kg) ................................... 2556 (1159)

Capacities

Fuel T ank V olume gal (L) ................................... 56 (212)

Usable Fuel Volume gal (L)................................ 56 (212)

Coolant (incl. engine) qt (L)................................. 11.6 (11.0)

Oil (incl. filter) qt (L)............................................ 8.6 (8.1)

Maximum Run Time hrs...................................... 31

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SPECIFICATIONS

Lighting

Lighting Type....................................................... Metal Halide

Ballast Type........................................................ Coil & Core

Lumens ............................................................... 440,000

Coverage acres (m2)........................................... 5 - 7 (20,234 - 28,328)

AC Distribution

Circuit Breaker Size............................................ 90

Volt age Selection................................................ 3 Position Switch (lockable)

Volt age Regulation .............................................. +/-1%

Volt ages Available 1Ø ......................................... 120, 139, 208, 220, 240, 277

Volt ages Available 3Ø ......................................... 208, 220, 440, 480

Trailer

Number of Axles ................................................. 1

Capacity - Axle Rating lbs (kg) ........................... 3000 (1361)

Tire Size in ......................................................... 15

Hitch - Standard.................................................. 2" Ball

Maximum Tire Pressure psi ................................ 50

Page 10

EXTERIOR LOCATIONS

1. FUEL FILLER LOCA TION (under door): Use clean DIESEL FUEL ONL Y .

2. RADIA T OR ACCESS P ANEL: Remove this panel for engine coolant service.

3. CONTROL P ANEL LOCA TION (under door): Engine/generator controls and all circuit breakers.

4. EMERGENCY STOP SWITCH: For emergency shut down; stops engine and trips main circuit breaker .

5. EQUIPMENT OUTLETS: Circuit breaker protected outlets; 20, 30 and/or 50 amp ratings.

6. GROUND STUDS (2): For grounding generator and equipment connected to the equipment outlets.

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MAIN CONTROL PANEL COMPONENTS

1. MAIN CIRCUIT BREAKER (90A): This breaker will disconnect power to the connection lugs.

2. LUG DOOR SAFETY SWITCHES: These switches will shut the generator down if the lug door is opened when the generator is running.

3. GENERAT OR OUTPUT CONNECTION LUGS: These allow appropriate loads to be wired directly to the generator.

4. GENERAT OR GROUND CONNECTION LUG: This lug is for connecting a good earthen ground per any local, state or National Electric Code (NEC) guidelines before starting the generator .

5. REMOTE START TERMINAL BLOCK: Allows connections for remote st arting of the generator.

6. CABLE ACCESS: Allows for entry of load cables to the connection lugs with the lug box door closed.

7. PHASE SELECTOR SWITCH: This switch will change the generator output between three phase and single phase power. See the VOL T AGE SELECT OR SWITCH section for more information.

8. VOLT AGE ADJUSTMENT RHEOSTA T : Used to fine tune generator output voltage.

9. CONTROL POWER SWITCH: This is the main power switch for the controller in MANUAL or AUTO mode.

10. ENGINE CONTROL PANEL: See p ages 12 - 13 for additional information.

11. BALLAST INDICA TOR LIGHTS: Indicates power from the ballast to each light.

12. INDIVIDUAL CIRCUIT BREAKERS: One breaker is supplied for each light.

13. AUXILIARY OUTLET MAIN CIRCUIT BREAKER (100A): This breaker disconnects power to the auxiliary equip- ment outlets.

Page 12

MAGNUM DIGIT AL CONTROLLER (MDC)

The Magnum Digital Controller (MDC) is an enhanced digital generator controller used to start, stop and monitor the operation of the generator and the engine. The controller constantly monitors vital generator and engine functions for a number of pre-programmed alarm and fault conditions. When a fault condition occurs, the engine will shut down automatically and the Liquid Crystal Display (LCD) window will display the fault that caused the shutdown; to resume operation the fault condition must be resolved. The controller has the ability to provide the display readout in English and Sp anish; other languages are available. A screen print out of the display screen is also available. This controller also records a “History” of the unit’s performance which may be viewed at any time and will not be removed or lost when the controller is powered down.

MAN AUT

Ready PF 0.00 RPM 0

The MDC panel consists of five sections, including: the “CONTROL ON” / “CONTROL OFF” Toggle Switch and Fine Volt age Adjustment Screw; the “OPERA TION” keyp ad; the LCD window; the “DIAGNOSTICS” keypad; and the “ST A TUS” Light Emitting Diodes (LED’s). The following is a brief summary of the operation of each section of the control panel:

1. The “CONTROL ON” / “CONTROL OFF” Toggle Switch and Fine Voltage Adjustment Screw

• Control On/Off T oggle Switch

This toggle switch powers-up the control panel and the controller.

• Fine Volt age Adjustment Screw

This screw may be adjusted to set the generator output voltage after the voltage selector switch has been changed from one phase to another. This adjustment must be accomplished within 45 seconds of start-up so that the unit does not experience a shut down alarm for “SENSING”.

2. The “OPERA TION” Keypad

• “ENGINE STAR T” Button

The Power Screen Display must be in the “MAN” mode in the upper left corner of the LCD window and the “Ready/Manual” LED lit in the “Status” portion of the controller . Press the green “ENGINE ST AR T” button to start the unit.

• “ENGINE STOP” Button

Press the red “ENGINE STOP” button to shut down the unit and start the “S top V alue” timer.

• “MANUAL W” Button

Press this button to change from the Automatic (Remote) starting mode to Manual st arting mode.

• “AUTO

X” Button

Press this button to change from Manual starting mode to Automatic (remote) st arting mode.

Page 13

• “ALARM CANCEL” Button

When an alarm is activated, either visually or audibly , press this button to silence or cancel the alarm.

• “FAUL T RESET” Button

Press this button to clear the fault from the LCD window after the fault has been corrected. Press “FAUL T RESET” and “ENTER” to clear the John Deere ECU Alarm List Codes.

3. The Liquid Crystal Display (LCD)

• This window will toggle between the Generator Display Screen and the Engine Display Screen upon start-

up of the unit. By viewing these screens, the operator will be able to monitor both the engine and generator status while the unit is running.

4. The “DIAGNOSTICS” Keypad

•“S” Scroll-Up Button

Press this button to scroll-up within the LCD window.

•“T” Scroll-Down Button

Press this button to scroll-down within the LCD window.

• “P AGE SELECT” Button

Pressing this button will select the next display screen.

• “ENTER” Button

Pressing this button will place you inside the particular display to review the generators preprogrammed setpoints or parameters.

5. The “ST A TUS” Light Emitting Diodes (LED’ s)

• These 6 LED’s will illuminate to display the current operational status of the generator;

- Alarm/Fault: Indicates active or inactive alarms, but not reset shutdown alarms.

- Warning: Indicates an active or inactive alarm, or a warning alarm that has not been reset

- Ready/Manual: Indicates the controller is ready to start and in the manual mode.

- Ready/Auto: Indicates the unit is in the “AUTO” mode ready for the remote start signal.

- Running: Indicates the unit is running.

- Supplying Load: Indicates a load is being applied to the generator.

GENERATOR MONITORING

Generator information is shown on the Liquid Crystal Display (LCD) window in a toggling manner with the Engine information after the first 60 seconds of operation, then every five seconds thereafter . The generator display screen will show frequency , line to neutral voltage, line to line voltage and amperage.

Note: When loading the generator , it is import ant to observe the amperage to determine the load balance on each line of the generator. Minor load unbalances, usually 5% or less, will not cause any particular problems. Every effort should be made to distribute the load equally between all lines.

• Hertz: Displays output frequency .

• Generator Output V olt age: Line to Neutral display, single phase (1Ø).

• Generator Output V olt age: Line to Line display, 3 phase (3Ø).

• Amps: Displays the AC output amperage produced by the generator .

Page 14

ENGINE MONITORING

Engine information is shown on the Liquid Crystal Display (LCD) window in a toggling manner with the Generator information after the first 60 seconds of operation and then every 5 seconds thereafter . The engine display screen will show oil pressure, engine coolant temperature, fuel level and battery voltage.

• Oil Press: Displays engine oil pressure. The display registers oil pressure between 0-100 psi. Normal operating pressure is between 35-80 psi.

• Eng T emp: Displays the temperature of the engine’s coolant. If the coolant temperature exceeds the Maximum Water Temperature of 230° F the engine will automatically shut down. Zero “0” will be displayed until a minimum temperature of 100° F is reached.

• Fuel Level: Displays the relative fuel level in the fuel tank in percent (50% = 1/2 tank, 75% = 3/4 tank, etc.). If the fuel level drops below a programmed low fuel point – usually at 15%, a low fuel warning and optional audio alarm will be activated. If the fuel level drops below the programmed low fuel limit, usually at 5%, the engine will automatically shut down. (Note: The MLG 25 does not display fuel level).

• Vbat: Displays the engine battery voltage. A normal reading is 13-14V on 12 volt systems and 24-26 on 24 volt systems, (with the engine running).

Additional information may be viewed while the unit is in “MANUAL” or “AUTO” mode. By pressing the “Page Select” button, the operator will select one of the following screens; “Running” screen, “Password” screen, or “History” screen. In each of these page selections the operator may press the “S” or “T” buttons on the “DIAGNOSTICS” keypad to display additional information as follows:

• “Running” screen:

The operator may press the “S” or “T” buttons on the “DIAGNOSTICS” keypad to display the “Alarm List” screen, “ECU Alarm List” screen, “Run Hours” screen, “ECU V alues” screen, Engine display screen and Generator display screen.

• “Password” screen:

The operator may press the “S” or “T” buttons on the “DIAGNOSTICS” keypad to move the “>” cursor up or down a list of text.

• “History” screen:

The operator may press the “S” or “T” buttons on the “DIAGNOSTICS” keypad to move the “>” cursor up or down a list of the latest alarm or shutdown codes. Pressing the “Enter” button at a particular selection will allow the operator to scroll to the right in the LCD window to view the generator operating parameters at the time of the alarm or shutdown.

Page 15

The history of alarms or codes of the unit are saved in the digital controller. The most

recent alarm or code is the first to be listed, with the time/date of the alarm or code at the bottom of the screen. The controller stores up to 1 18 codes. When full, the controller will automatically remove the oldest file. These codes will not be lost when the control power toggle switch is powered off.

FINE VOLTAGE ADJUSTMENT

Upon start-up of the generator , the “Running” screen of the Magnum Digital Controller (MDC) will display “SENSING” and will countdown from 45 seconds to “0” Zero. This is a safety feature of the controller to protect the generator from over or under voltage upon start-up.

VOLTAGE DJUSTMENT RHEOSTAT

CONTROL

OFF

“SENSING” is a 45 second time delay and count down process before the MDC records the generator nominal output voltage. This nominal generator voltage is then compared to the current set point voltage of the voltage selector switch. If the nominal voltage recorded by the controller is greater than or lower than the current set point voltage of the voltage selector switch setting by 10% or more, the controller will shut the generator down automatically . The display will read: Wrn VG1 or 2 or 3 Under/Over and/or Sd Vg1 or 2 or 3 Under/Over. This means the controller warned (“Wrn”) or even shut down (“Sd”) the unit due to an output voltage irregularity .

The output voltage of the generator may be adjusted after the generator is running by use of the fine voltage adjustment screw. The adjusting screw is located directly below the control On/Off toggle switch on the control panel. This screw turns a rheostat that will provide an increase (“+”) or a decrease (“-”) in the generator output voltage as displayed on the Power Display Screen on the control panel. When making this adjustment, if the voltage is increased or decreased too fast or too slow, the unit will automatically shut down. This adjustment needs to be made within the 45 second delay and countdown to “0” Zero period.

T o adjust the output voltage, check the output voltage on the Liquid Cryst al Display (LCD) window labeled Gen freq & Hz. Look at the L1N voltage or the L12 voltage on the display . The generator nominal output voltage should be within 10% of the voltage rating on the voltage selector switch.

To adjust the output voltage loosen the lock nut at the base of the screw and turn the screw in the desired direction until the required voltage shown on the LCD window matches the stated voltage on the voltage selector switch.

For Example: With the voltage selector switch set to “208/120V” 3 Phase position, the voltage displayed on

the Gen freq & Hz screen must be within ± 10 % of the 208/120 position (188-228 V Line to Line / 108-132 V Line to Neutral).

If the voltage is not set within 10% of the applied voltage or the voltage is not reset within the 45 second delay period, the generator will shut down automatically and the display will read Wn VG1 or 2 or 3 Under/Over and/or Sd Vg1 or 2 or 3 Under/Over.

Note: Each time the voltage selector switch is changed from one setting to another, an adjustment will need to be made to the fine voltage using this adjustment screw.

Page 16

MAGNUM DIGITAL CONTROLLER (MDC) INFORMATION DISPLAYS, FUNCTIONS AND

No. Engine State Machine Description

1 AfterCool Engine aftercooling, Cooling Pump output is closed.

2 Cooling The generator is cooling before stop.

3 Cranking Engine is cranking.

4 EmergMan Emergency Manual gen-set operation.

5 Init Autotest during controller power on.

6 Loaded

The generator is running at nominal speed and GCB OPEN/CLOSE is closed.

7 Not Ready The generator is not ready to start.

8 Pause Pause between start attempts.

9 Prestart Prestart sequence in process, Prestart output is closed.

10 Ready The generator is ready to run.

11 Running The generator is running at nominal speed.

12 Shutdown Shut-down alarm is activated.

13 Starting Starting speed is reached and the

Idle timer

is running.

14 Stop Stop

No. Electrical State Machine Description

1 StabilTO Stabilization Timeout

No. Type Description

1 Sensor fail (FLS)

Sensor fail is detected when measured value is 6% out of the selected characteristic. Sensor fail indicated by ##### symbol instead measured value.

2 Warning (WRN) When warning comes up, see list of possible alarms.

3 Shut down (SD)

When the shut-down alarm comes up the Magnum Digital Controller opens outputs GCB CLOSE/OPEN, FUEL, SOLENOID, STARTER AND PRESTART to stop the engine immediately.

RESET

The Magnum Digital Controller (MDC) constantly monitors vital generator and engine functions for a number of operation, alarm and fault conditions. When a fault condition occurs, the engine will shut down automatically and the Liquid Crystal Display (LCD) window will show the fault that has caused the shut down. To resume operation, the fault condition must be resolved. T o reset the controller and resume operation, press the “F AUL T RESET” button.

MAGNUM DIGITAL CONTROLLER (MDC) – GENERATOR OPERATIONAL STATUS

The Magnum Digital Controller (MDC) displays the operational status of the generator using the following codes:

MAGNUM DIGIT AL CONTROLLER (MDC) - ALARM MANAGEMENT

The Magnum Digital Controller (MDC) is capable of displaying the following alarms:

Page 17

MAGNUM DIGITAL CONTROLLER (MDC) - LIST OF POSSIBLE ALARMS/DESCRIPTIONS

No.

Events

Specification

Protection

Type

Information

on Binary

Output

Available

Description

1 AnInIOM Sd SD YES

Shutdown alarm configurable on the input of IG-IOM/IGS-PTM.

2 AnInIOM Wrn WRN YES

Warning alarm configurable on the input of IG-IOM/IGS-PTM.

3 Battery Flat SD YES

If the controller switches off during starting sequence due to bad battery condition it doesn't try to start again and activates this protection.

4 Binary Input Configurable YES

Configurable Warning/Shutdown alarms on the inputs of IL-NT.

5 ChrgAlternFail WRN YES

Failure of the alternator for charging the battery.

6 EmergencyStop SD NO

If the input

Emergency stop

is opened shutdown is immediately

activated.

7 Engine Temp Sd SD NO

Water temperature is greater than

Sd Water temp

setpoint.

8 Engine Temp Wrn WRN YES

Water temperature is greater than

Wrn Water temp

setpoint.

9 Fgen <, > SD YES

The generator frequency is out of limits given by

Gen >f

and

Gen <f

setpoints.

10 Fuel Level Sd SD YES

Fuel level is less than

Sd Fuel Level

setpoint.

11 Fuel Level Wrn WRN YES

Fuel level is less than

Wrn Fuel Leve

l setpoint.

12 GCB fail SD NO

Failure of the generator circuit breaker.

13 Igen unbl SD NO

The generator current is unbalanced.

14 Low BackupBatt WRN NO

RTC backup battery is flat.

15 Oil Press Sd SD NO

Oil pressure is less than

Sd Oil press

setpoint.

16 Oil Press Wrn WRN YES

Oil pressure is less than

Wrn Oil press

setpoint.

17 Overload SD YES

The load is greater than the value given by

Overload

setpoint.

18 Overspeed SD YES

The protection comes active if the speed is greater than

Overspeed

setpoint.

19 ParamFail NONE NO

Wrong checksum of parameters. Happens typically after downloading new firmware or changing of the parameter. The controller stays in INIT mode. Check all parameters write at least one new parameter.

20 PickupFault SD NO

Failure of the magnetic pick-up sensor for speed measurement.

21 Sd IOM fail SD NO

Shutdown alarm in case of lost connection to IG-IOM/IGS-PTM module.

22 SprinklActive WRN NO

The protection is active if the output

Sprinkler

is closed.

23 Start failed SD YES

Gen-set start failed

24 Stop fail SD YES

Gen-set stop failed.

25 Ubat WRN YES

Battery voltage is out of limits given by

Batt overvolt

and

Batt

undervolt

setpoints.

26 Underspeed SD YES

During starting of the engine when the RPM reaches the value of

Starting RPM

setpoint the starter is switched off and the

speed of the engine can drop under

Start RPM

again. Then the Underspeed protection becomes active. Protection evaluation starts 5 sec

27 Vgen <, > SD YES

The generator voltage is out of limits given by

Gen <V

and

Gen >V

setpoints.

Shut down and warning fault conditions and the displayed message are described in the following table:

Page 18

28 Vgen unbal SD NO

The generator voltage is unbalanced more than the value of

Volt unbal

setpoint.

29 Wrn ECU Alarm WRN NO

ECU alarm list is not empty.

30 Wrn RA15 fail WRN NO

Warning alarm in case of lost connection to IGL-RA15 module.

31 WrnServiceTime WRN NO

The period for servicing is set by the

NextServTime

setpoint. The protection comes active if the running hours of the engine reach this value.

MAGNUM DIGIT AL CONTROLLER (MDC) – HIST OR Y

No.

Record Structure

Abbreviation

Historical value

1 AIM1 IG-IOM, IGS-PTM Analog input 1 value (when configured IG-IOM, IGS-PTM)

2 AIM2 IG-IOM, IGS-PTM Analog input 2 value (when configured IG-IOM, IGS-PTM)

3 AIM3 IG-IOM, IGS-PTM Analog input 3 value (when configured IG-IOM, IGS-PTM)

4 AIM4 IG-IOM, IGS-PTM Analog input 4 value (when configured IG-IOM, IGS-PTM)

5 BIM IG-IOM, IGS-PTM Binary inputs (when configured IG-IOM, IGS-PTM)

6 BIN Binary inputs IL-NT

7 BOM IG-IOM, IGS-PTM Binary outputs (when configured IG-IOM, IGS-PTM)

8 BOUT Binary inputs IL-NT

9 Date Date of historical event in format DD/MM/YY

10 EngT IL-NT Analog input 2 value (default Water temperature)

11 FC ECU alarm FailureCode

12 FLvl IL-NT Analog input 3 value (default Fuel level)

13 FMI ECUalarm Failure Mode Identifier

14 Gfrg Generator frequency

15 Ig1 Generator current L1

16 Ig2 Generator current L2

17 Ig3 Generator current L3

18 LChr Character of the load

19 Num Number of historical event

20 OilP IL-NT Analog input 1 value (default Oil pressure)

21 PF Generator PF

22 Pwr Generator active power

23 Reason Event specification

24 RPM Engine Speed

25 Time Time of historical event in format HH:MM:SS

26 Ubat Battery voltage

27 Vg1 Generator voltage L1

28 Vg2 Generator voltage L2

29 Vg3 Generator voltage L3

The Magnum Digital Controller (MDC) controller stores a record of each important event into the history file of the controller. The history file seat s 1 18 records. When the history file is full, the oldest records are removed.

Page 19

ADJUSTING THE DISPLAY BACK LIGHTING

The backlighting on the Liquid Crystal Display (LCD) window may be adjusted brighter or darker by the operator whenever the Magnum Digital Controller (MDC) is powered up.

1. Press and hold “Enter” and press “S” or “T” on the Diagnostics keypad to increase or decrease the display contrast as needed.

2. Release the “Enter” button and the “S” or “T”buttons when the desired backlighting is attained.

Note: Anytime an “*” is displayed on the LCD, the text or set point cannot be changed with out the use of a pass- word. Contact Magnum Products Technical Support for assistance.

RESETTING OF THE “TIME TO SERVICE” REMINDER

The Magnum Digital Controller (MDC) will display the message “ WrnServiceTime” when the unit is due for maintenance or service. The maintenance or service interval is set at 250 hours of engine running time. Once the unit has been serviced, the “ServiceTime” reminder needs to be reset to the 250 hour interval. The following procedure demonstrates how to reset the running hours to 250:

1. With the unit shut down, power up the controller with the “Control On/Off” T oggle Switch. The initialization screen will be displayed. The controller will toggle automatically to the “Ready” Display screen.

2. Press the “S” button. The “Alarm List” display screen will appear. The next screen will display lines of text; starting with the word “Password”, then “Basic Settings”, “Engine Params”, “Engine Protect” etc. The top line has a “> “ cursor before the word ‘Password”.

3. Press the “T” button to move the “> “cursor down to the “Engine Protect” line of text.

4. Press Enter. “NextServTime” will appear at the top of the display screen on the left side, with the current service time hour setting (250) one line below on the right side

5. Press Enter. The current run time in hours will now appear on the left side of the display screen, directly under “NextServTime”

6. Press the “S” button and reset the current run time hour setting to 250. If you overshoot the 250 time interval use the “T” button to get back to the 250 time interval.

7. Press “Enter” to save the current run time hour setting.

8. Move the “CONTROL ON / I” toggle switch to the “CONTROL OFF / O” position.

Page 20

TIGHTEN CONNECTION

LUGS WITH A HEX WRENCH

GENERATOR OUTPUT CONNECTION LUGS

The generator is equipped with connection lugs behind a door below the controller face. The lugs provide connection points for attachment of external loads to the generator . A large decal on the inside of the connection lug door details the proper connections for selected voltages.

WARNING

It is HIGHLY RECOMMENDED that only a trained and licensed electrician perform any wiring and

related connections to the generator. Installation should be in compliance with the National

Electric Code (NEC) as well as any local or state guidelines as required by law. Failure to follow

proper installation requirements may result in equipment or property damage, personal injury

or death.

WARNING

Before any connections are made to the generator, make sure that the main circuit breaker and

the control power switch are in the OFF “O” position. Potentially lethal voltages may be present

at the generator connection lugs.

DANGER

IMPROPER OR INCORRECT CONNECTIONS TO A BUILDINGS ELECTRICAL SYSTEM CAN CAUSE

POTENTIALL Y LETHAL VOL T AGE T O BACKFEED ONTO UTILITY LINES. THIS MA Y RESUL T IN

INJURY OR ELECTROCUTION T O UTILITY WORKERS NEARBY . MAKE SURE THE GENERA TOR IS

SUPPL YING POWER TO AN ISOLA TED OBJECT OR BUILDING THA T IS NOT CONNECTED T O ANY

UTILITY LINES.

Connections to the lugs should be made by running the power cables through the circular plastic bushing on the lower right side of the control box. DO NOT make any connections directly to the lugs without routing the cables through this bushing. The lug door is equipped with safety interlock switches that will automatically trip the main circuit breaker and disable the voltage regulator when the lug door is opened. Use a hex-wrench to tighten the cable connections.

WARNING

Never attempt to disable or modify the lug door

safety switches. Equipment damage, personal

injury or death may result.

A ground connection is located next to the connection lugs. The unit MUST HAVE this ground lug connected to a good earthen ground for proper operating safety . The ground connection should be in compliance with the National Electric Code (NEC) as well as any state or local guidelines or codes.

Page 21

VOLTAGE SELECTOR SWITCH

The voltage selector switch is located behind the lug door , underneath the engine controller panel. The selector switch is a three position switch that mechanically changes the connections between the generator output leads and the connection lugs. Voltage ranges are selected by rot ating the handle on the switch to the desired voltage.

NOTICE

Never change the voltage selector switch while the engine is running!

This will cause sever arcing and damage to the switch and generator windings.

480/277V 3-PHASE

208/120V 3-PHASE

208 120

480 277

208 120

T10

T11

T12

L-N

L-L

L1 - L2 = 480V L1 - N = 277V L2 - L3 = 480V L2 - N = 277V L3 - L1 = 480V L3 - N = 277V N =

L1 - L2 = 208V L1 - N = 120V L2 - L3 = 208V L2 - N = 120V L3 - L1 = 208V L3 - N = 120V

480 277

240 120

T12

T10

T11

L-N

L-L

N =

240/120V 1-PHASE

208 120

240 120

T12

240V

T11

T10

T4 T1

120V120V

L1 - L3 = 240V L2 - N = ------L1 - N = 120V L3 - N = 120V

The voltage switch is equipped with a locking mechanism. Once the proper voltage has been selected, push the red latch on the inside of the phase switch handle up and insert a padlock through the handle. By locking the handle in place you will prevent unauthorized personnel from changing the switch settings.

Note: When the voltage selector switch is in position for 480/277V 3Ø, voltage at the two GFCI duplex convenience outlets is 139 Volts and the voltage at the three twist-lock outlets is 240/139 Volts. When the voltage selector switch is in position for 208/120V 3Ø, voltage at the three twist-lock outlets and the two GFCI outlets is 208/120 Volts.

Page 22

AUXILIARY OUTLETS

The control panel is equipped with six outlets for running accessories or tools from the generator. Power is supplied to the outlets any time the engine is running and the main circuit breaker and the auxiliary outlet main circuit breaker are switched in the ON “I” position.

Should the main breaker trip, or the auxiliary outlet main circuit breaker trip, remove some of the load to the outlets before turning them back on.

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 outlet panel per any local, state or NEC codes and guidelines.

AUXILIARY OUTLET GROUNDING STUD

VOLTAGE REGULATION

The electronic 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 under frequency (U/F). The voltage regulator on your unit is adjusted before shipment from the factory . Contact Magnum Products LLC for additional information before attempting to adjust the voltage regulator .

EMERGENCY STOP SWITCH

The generator is equipped with one emergency stop switch, located on the side panel next to the auxiliary outlet panel. The switch is clearly labeled with “EMERGENCY ST OP” and is red in color . The switch can be accessed and activated with all doors closed and locked.

Activate the emergency stop switch by pushing the red button in until it locks down. This will trip the main circuit breaker which will open the contact disconnecting the load to the connection lugs. This will also open the fuel circuit, shutting down the engine and the Emergency Stop fault will be displayed on the LCD. The switch will remain closed until it is pulled out. Note: Use the EMERGENCY STOP only when the generator must be shut down

immediately . For any other shut down, follow the detailed shut down procedure.

Page 23

MAIN CIRCUIT BREAKER

The main circuit breaker is located on the main control panel. When the breaker is in the OFF “O” position, power is interrupted between the customer connection lugs and the generator. Once the connections have been made to the connection lugs and the generator has been started and allowed to reach normal operating temperature, the breaker may be switched to the ON “I” position.

The main circuit breaker will be tripped, disconnecting power to the connection lugs, if any of the following items occur while the unit is running:

1. Overload of the generator circuits to the connection lugs.

2. The lug box door covering the customer connection lugs is opened.

3. If the emergency stop switch is activated.

Make sure that any problems that caused the main circuit breaker to trip are corrected before returning the switch to the ON “I” position.

NOTICE

The main circuit breaker interrupts power to the customer connection lugs only . The customer convenience outlets

have power even if the main circuit breaker is in the OFF “O” position. The auxiliary outlet main circuit breaker ,

located next to the main circuit breaker, will disconnect all power to the auxiliary outlet panel.

REMOTE START TERMINAL BLOCK

The remote start terminal block is located under the lug box door just below the voltage selector switch. It provides a connection for installation of a remote start switch which will allow the generator to be started by a remote drycontact closure switch.

Before pressing the AUT O button, verify that the contacts on any remote switch linked to the generator are OPEN. If the contacts on a remote switch are closed, the generator will crank and start when AUTO is selected on the controller . Attach the switch leads to the two unused terminals on the generators remote start block. For additional information on starting the generator , see the GENERATOR ST ART UP section of this manual.

TRANSFER SWITCH

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 ISOLA TE THE GENERA TOR FROM THE NORMAL POWER UTILITY CAN CAUSE

POTENTIALL Y LETHAL VOL T AGE TO BACKFEED INT O THE UTILITY LINES. THIS MA Y RESUL T IN

INJURY OR ELECTROCUTION OF UTILITY WORKERS NEARBY . MAKE SURE THA T THE GENERA TOR IS

ISOLA TED BY A TRANSFER SWITCH FROM ANY LOCAL UTILITY LINES. THIS ALSO APPLIES IF THE

GENERA TOR IS BEING USED AS A BACK UP TO SOME OTHER TYPE OF POWER SUPPL Y.

Page 24

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 generator to a power supply normally serviced by a utility company , notify the utility company and check local and state regulations. Familiarize yourself with all instructions and warning labels supplied with the switch.

WARNING

It is strongly recommended that ONLY a licensed electrician perform any wiring and any related

connections to the generator. Installation should be in compliance of the National Electric Code as

well as any state or local codes or 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 engine start switch are in the OFF “O” position and that the negative (-)

battery cable has been disconnected from the engine starting battery.

NOTICE

When using the generator as a stand by 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.

INCOMING

UTILITY POWER

UTILITY

METER

POWER FROM

GENERATOR

WHITE = INCOMING UTILITY POWER

EMERGENCY

DISTRIBUTION PANEL

(GENERATOR POWER)

MAIN DISTRIBUTION

PANEL

(UTILITY POWER)

TRANSFER

SWITCH

GRAY = NORMAL UTILITY POWER CIRCUIT

BLACK = EMERGENCY GENERATOR POWER CIRCUIT

Page 25

LIGHT TOWER SET-UP

1. For maximum light coverage locate tower at ground level or in a spot higher than the area being illuminated by the lamps.

WARNING

Check for any overhead obstructions such as utility lines or vegetation as the tower extends up

to 30 ft. (9.14 m). Do not set up the tower if high winds or storms capable of producing lightening

are expected in the area!

DETAIL C

DETAIL D

2. Place the trailer on firm ground that is relatively flat. This will make it easier to level the tower.

Block the wheels on the trailer to keep it from moving (A).

3. Pull the locking pin on the tongue jack and rotate it 90º until the spring loaded pin snaps back into place

(B). Turn the jack handle clockwise to raise the trailer tongue off of the towing vehicle.

4. Connect a good earthen ground to the grounding stud on the frame of the trailer near the trailer tongue (C).

5. Pull the locking pins (D) on the outriggers (E) and pull the outriggers out until the spring loaded locking pin snaps

back into place. Pull the locking pin on the outrigger jacks and rotate them 90º until the spring loaded pin snaps back into place.

DETAIL G

DETAIL H

6. Pull the locking pin on the rear jack (F) and rotate it 90º until the spring loaded pin snaps back into place. Turn the

jack handle clockwise to start leveling the trailer. Adjust all four jacks by turning their handles clockwise until they are firmly in contact with the ground and the trailer is as level as possible (G).

7. Before raising the tower it may be necessary to adjust the lamps. The lamps may be adjusted up, down, left or right

by loosening the wing bolts on the lamp fixture (H) and aiming them in the desired direction. Tighten the hardware completely and make sure the lamps are connected to the junction box.

Page 26

RAISING THE TOWER

WARNING

The trailer must be leveled with the outriggers extended before raising the tower. The outriggers

must remain extended while the tower is up. Failure to level the trailer or extend the outriggers

will severely reduce the stability of the unit and could allow the tower to tip and fall.

1. Remove the mast cradle locking pin from the mast cradle (I).

2. Check both sets of mast cables for excessive wear or damage. Make sure the cables are properly centered in each pulley (J). Check the electrical cord for damage.

WARNING

Do not start the unit if the insulation on the electrical cord is cut or worn through.

Bare wires in contact with the mast or frame may energize the trailer and cause electrocution.

Repair or replace cord.

3. Make sure the area behind the unit is clear before raising the mast to the vertical position.

4. Remove the safety pin (K) from the mast lock bar (L). Using the handle for the lower mast winch (M), 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 (N).

DETAIL I DETAIL K

DETAIL N

STOP

5. After the mast is up and locked into place, use the upper mast winch (O) to telescope the tower to the desired height. Extend the mast slowly, making sure that 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 tower 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 (P).

6. The mast can be rotated by loosening the locking knob at the bottom of the mast (Q). Turn the mast until the lights face in the desired direction and then tighten the knob.

WARNING

Never raise or lower the mast while the unit is

operating! Never remove the safety pin or mast

lock while the tower is up. Releasing the lock

will cause the mast to fall.

DETAIL P

K, L, N

Page 27

RAISING THE TOWER WITH THE OPTIONAL ELECTRIC WINCH

1. Set up and level the trailer as described on page 25, and follow steps 1-3 on page 26.

2. Remove the safety pin from the mast lock bar (R).

3. Press the lower winch control toggle switch upward to raise mast into the vertical position (S). Hold switch until the mast lock is engaged. The mast lock bar should snap into place automatically . Note: On light towers equipped

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.

4. Secure the lock with the safety pin (T).

DETAIL R

5. Press and hold the upper winch control toggle switch upward to telescope the mast to desired height (U). 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 tower sections get stuck, STOP IMMEDIA TEL Y and cont act an authorized service center.

CAUTION

Do not extend the mast beyond the colored mark

on top of the lower mast section (V). On light towers equipped with the electric winch option, a limit switch on the main mast section will disconnect power to the upper electric winch to prevent

over extending the mast.

6. The mast can be rotated by loosening the locking knob at the bottom of the mast (W). Turn the mast until the lights face in the desired direction and then tighten the knob.

DETAIL S

DETAIL T

DETAIL U

STOP

DETAIL V DETAIL W

WARNING

Never raise or lower the mast while the

unit is operating! Never remove the safety

pin or mast lock while the tower is up.

Releasing the lock will cause the mast to fall.

R,T W

Page 28

LIGHT TOWER START UP

Before starting the light tower, carefully read the pre-st art check list. Make sure that all of the items are checked before trying to start the light tower. This check list applies for both manual and remote starting.

PRE- START CHECK LIST

 Make sure the control ON/OFF toggle switch is in the OFF “O” position.  Make sure that the circuit breakers (main and convenience) are switched OFF “O”.  Check that the light tower is properly grounded to a good earthen ground per any local and NEC

regulations.

 Check all electrical connections at the connection lugs. Are they wired correctly?  Are the connection lugs tight?  Check that the voltage selector switch is set to the desired voltage.  Is the voltage selector switch locked?  Is the light tower sitting level?  Check for any water inside, on, or near the unit. Dry the unit before starting.  Check oil, coolant and fuel levels and engine battery connections.  Check engine fan belt tension and condition.  Check engine fan belt guard.  Check engine exhaust system for loose or rusted components.  Check radiator and surrounding shroud for debris.  Are any of the generator covers loose or missing?  Are all preventative maintenance procedures up to date?  Check that the battery disconnect switch is on, if equipped.

MANUAL STARTING OF THE LIGHT TOWER

1. Move the control ON/OFF toggle switch to the “CONTROL ON / I” position.

2. The Liquid Crystal Display (LCD) window will quickly display system information, all Light Emitting Diodes (LED’s) will flash.

3. The LCD window will indicate MANUAL mode and Ready . The Ready/Manual LED will be lit. Note: The

unit must be in the “MAN” Mode with the Ready/Manual LED lit to start the unit.

Page 29

4. Press the green “ENGINE ST ART” button. The Prestart (Preheat) screen will be displayed (if equipped) and a countdown will begin from 20 seconds to 0.

5. The S tarting screen will be displayed. The engine will crank and start running.

6. The Running screen will display . Note: It may take a few seconds for the engine to run smoothly and

reach its governed operating speed. The 45 second “SENSING” time delay will start to count down.

7. The LCD window will then toggle from the Running screen to the Generator Display Screen and then to the Engine Display Screen.

8. 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 LCD window will show “P AUSE”. The engine will make two more attempts to start for a total of three crank cycles.

9. Should the engine not start and run within 3 starting cycles, the LCD window will show “SD Start fail”. The starting sequence may be repeated after the starter has had a minimum of two minutes to cool. Press the “FAULT RESET” button to clear the controller. To start the unit, press the green “ENGINE ST ART” button. Note: The engine controller may skip the preheat engine steps on some of the larger

models.

Page 30

10. Once the engine starts it will immediately begin speeding up to a constant 1800 rpm. On units with isochronous engine governing, the engine may hunt or change speeds until operating temperature is reached. Af ter a few minutes of operation, the engine will be warmed up and the LCD window will show engine and generator operating parameters. Temperature will be shown as “0” until the engine temperature is approximately 100° F.

1 1. Once the generator is at normal operating temperature, check the generator for excessive noise or

vibration and any coolant, oil or fuel leaks before applying any loads.

12. Check that the AC output voltage is correct. The output voltage can be fine adjusted by using the fine voltage adjustment screw (rheostat), as described on page 15.

13. Check that the frequency (Hz) is correct. With no loads connected to the generator , the frequency should read approximately 60-62 Hz, depending on the type of engine governing used.

14. 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 convenience outlets by switching the respective circuit breaker to the “ON / I” position. Y ou will notice a slight change in engine sound when a load is applied to the unit.

“AUTO” (REMOTE) STARTING OF THE LIGHT TOWER

The “AUTO” button is used when the generator is started from a location other than the control panel and by using a dry-contact closure remote start switch (transfer switch). “AUTO” (remote start) is the normal setting when the generator is being used as a standby power supply . Before putting the generator in the “AUTO” mode, review the Pre-Start Check List and Manual S tarting of the Generator sections beginning on p age 28. Also follow all safety warnings and information on isolating the generator with a transfer switch if the unit is to be used as a standby power supply , as described on pages 23 and 24. Then continue with the steps described below:

1. Perform a manual start of the generator at least once to verify that the engine is operating correctly.

2. If a check of the remote start circuit is desired, remove the wires from the remote start terminal block. Press the “AUTO” button, the Liquid Crystal Display (LCD) window should highlight “AUTO” in the upper left corner . Att ach a jumper wire (minimum 16 gauge) across the two terminals on the remote start terminal block. This applies a ground to the Magnum Digital Controller (MDC) to close the starting circuit contacts. The engine should crank, start and run.

3. Remove the jumper wire from the remote start terminal block and the engine will stop. Reconnect any necessary wires from the remote start switch (transfer switch) to the remote start terminal block.

4. Confirm unit is in “AUTO” mode. The LCD window should have “AUT” highlighted in the upper left corner.

5. Close (set to “ON / I”) the main circuit breaker.

6. Secure the generator by closing and locking all access doors.

7. The generator is now ready for remote starting.

Page 31

LIGHT OPERA TION

1. Once the engine is up to temperature and running smoothly , switch main circuit breaker to the ON “I” position.

2. With main circuit breaker on, switch each individual circuit breaker for the lights to ON “I”, one at a time.

3. The green ballast indicator lights will come on momentarily as the lights strike. As the lights warm up, the ballast indicator lights will continue to get brighter and then remain on. This confirms that power is coming from the ballasts to the lights.

4. If an indicator light does not come on, the ballast may need to be serviced. If the indicator light comes on and stays lit but the related light is not illuminated, check the bulb or the mast wiring. Refer to the troubleshooting section on page 37.

5. 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 cooldown period of approximately 10 minutes before they can be switched on again.

6. 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.

WARNING

NEVER OPERA TE 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.

CAUTION

Bulbs become extremely hot when in use! Allow bulb fixture to cool

10-15 minutes before handling or lowering tower.

SHUTTING DOWN

When you have finished using the light tower, proceed with shut down as follows:

1. Remove any loads from the auxiliary outlets.

2. Switch the individual circuit breakers for each light to the OFF “O” position.

3. Switch the main circuit breaker to the OFF “O” position.

4. Push the red “ENGINE STOP” button. Pressing “Engine Stop” will result in the light tower going into the shutdown cycle and starting a 15 second shutdown timer called “S top Value”. If the unit does not shutdown within 15 seconds a “Stop Fail” alarm will be displayed on the Liquid Crystal Display (LCD) window .

5. Move the “CONTROL ON / I” toggle switch to the “CONTROL OFF / O” position.

Page 32

LOWERING THE TOWER

1. Shut down the lights and engine. Allow the lights to cool 10-15 minutes before lowering the tower .

2. Turn the upper mast winch handle to collapse the tower to its lowest position. Make sure the electrical cord returns to the storage tube properly .

WARNING

If the mast hangs up or the winch cable begins to develop slack, STOP IMMEDIATELY!

Excess slack in the cable could cause the mast to collapse should it free up without warning.

Contact an authorized service center.

3. Loosen the mast rotation knob and rotate the tower so the mast mounted winches face the front of the unit. The white alignment arrow points should line up on the mast sections and the metal stop tabs should be touching. Tighten the mast rotation knob.

4. Release the mast lock by pulling the safety pin on the mast lock and pulling the lock free. Turn the handle of the lower mast winch until the mast spring begins to pivot the tower down. Release the mast lock and continue to lower the tower until it rests in the cradle. Note: If the mast lock does not pull free, operate lower winch

slightly to relieve pressure on the mast lock.

5. After the mast is completely down, insert the cradle lock pin and secure it with the safety pin.

6. If the trailer is going to be moved, Magnum Products LLC strongly recommends that the lights be removed from the mast and stowed for transportation. See REMOVING THE LIGHTS FOR TRANSPOR T A TION section on page 33.

LOWERING THE TOWER EQUIPPED WITH THE OPTIONAL ELECTRIC WINCH

1. Shut down the lights and engine. Allow the lights to cool 10-15 minutes before lowering the tower .

2. Loosen the mast rotation knob and rotate the tower so the mast mounted winches face the front of the unit. The white alignment arrow points should line up on the mast sections and the metal stop tabs should be touching. Tighten the mast rotation knob.

3. Press and hold the upper winch control toggle switch downward to collapse the mast to its lowest level. Make sure the coiled electrical cord on the top sections of the mast does not get tangled on the mast sections. 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 tower. If, for any reason, the cable begins to develop slack or any of the tower sections get stuck, STOP IMMEDIATELY and contact an authorized service center.

4. Release the mast lock bar by pulling the safety pin on the mast lock and pulling the lock bar free. Lower the mast by holding the lower winch control toggle switch to the right until the mast is resting in the transport cradle.

Note: If the lock bar does not pull free, activate lower winch slightly to relieve pressure on the mast lock bar.

5. After the mast is completely down, insert the cradle lock pin and secure it with the safety pin.

Page 33

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 other units, remove the junction box cover on the top of the mast and disconnect ONLY the mast light wires from the terminal blocks. To release the wires from the terminal blocks, flip the locking levers down and pull out the appropriate wires (A).

2. Remove the lights by removing the wing nut that holds the light fixture bracket to the cross tube. Attach the light s to the storage brackets (if equipped) located on the mast tube on either side of the central lifting eye.

TOWING THE TRAILER

Once the engine is shut down and the mast and lights are properly stowed, the trailer can be made ready for transport.

1. Raise the rear jack completely and release the locking pin to rotate it up into the travel position. Make sure the locking pin snaps into place.

2. Raise the outrigger jacks completely and release the jack locking pin to swing the jacks up into the travel position. Make sure the locking pins snap into place. Release the outrigger locking pins and slide the outriggers into the trailer frame until the locking pins snap into place.

3. Use the tongue jack to raise or lower the trailer onto the hitch of the towing vehicle. Lock the hitch coupling and attach the safety chains or cables to the vehicle. Release the jack locking pin and rotate the jack into the travel position. Make sure the locking pin snaps into place.

4. T o ensure proper operation of the jacks, lube the grease fittings located on the leveling jacks.

5. Connect any trailer wiring to the tow vehicle. Check for proper operation of the stop and signal lights.

6. Make sure the mast cradle locking pin is in place.

7. Make sure the doors are properly latched.

8. If the trailer is going to be driven over rough ground, remove the bulbs from the light fixtures.

9. Check for proper inflation of the trailer tires. The maximum tire inflation is 50 psi.

10. Attach a red flag to the end of the mast before towing.

11. Check the wheel lugs. Tighten or replace any that are loose or missing. If a tire has been removed for axle service or replaced, 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).

After the first road use, re-torque the lug nuts in sequence.

12. Maximum recommended speed for highway towing is 45 mph. Recommended off-road towing speed is not to exceed 10 mph or less depending on terrain.

TRAILER WHEEL BEARINGS

The generator is 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; more frequent lubrication may be required

under extremely dusty or damp operating conditions.

Page 34

LIFTING THE TRAILER

When lifting the light tower and trailer, att ach any slings, chains or hooks directly to the central lifting eye. The lifting eye is located on the mast between the two forklift pockets.

1. Make sure the equipment being used to lift the light tower has sufficient capacity. Note: See the unit specifica-

tions on pages 8 - 9 for approximate weights.

2. Make sure the mast cradle locking pin is in place.

3. Always remain aware of the position of other people and objects around you as you move the unit.

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 even routine service (oil/filter changes, cleaning, etc.) unless all electrical components are shut down. When servicing this equipment always follow the instructions listed below.

Before servicing this machine, make sure the control power switch is turned to OFF “O”, the circuit breakers are open (OFF “O”), the emergency stop switch is activated (pushed in), and the negative (-) terminal on battery is disconnected. Attach a “DO NOT ST AR T” 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. If the unit is connected to a remote start or transfer switch, make sure the remote switch is also off and tagged.

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. W ater 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 and dry the unit thoroughly before starting.

1. Inspect condition of electrical cords. DO NOT use light tower if insulation is cut or worn through.

2. Check that winch cables are in good condition and that they are centered on each pulley. DO NOT use a cable that is kinked or starting to unravel.

PROPER MAST CABLE ROUTING

3. 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.

4. Check the fuel, oil and coolant levels.

5. Check the operation of the trailer parking brake (if equipped).

6. Check the wheel lugs. Tighten or replace any that are loose or missing. If a tire has been removed for axle service or replaced, tighten the lugs in the order shown on page 33.

Page 35

ENGINE MAINTENANCE

Check

Daily

Every

Hours

Every

250

Hours

Every

500

Hours

Every

1000

Hours

Every

2 Years

Check Tire Pressures

■

Check Engine Oil Level

■

Check Engine Coolant Level

■

Check Fuel Level

■

Check Alternator Belt

■

Drain Fuel Filter*

■

Check Radiator Hoses

■

Change Engine Oil & Filter**

■■

Check All Electrical Connections

■

Check For Fuel Leaks

■

Replace Fuel Filter Element***

■

Inspect and Clean Radiator Fins

■

Lubricate Leveling Jacks

■

Clean Air Filter Element, replace if necessary

■

Replace Alternator Belt

■

Inspect Engine Starting Battery

■

Check Valve Clearance

■

Drain and Clean Fuel Tank

■

Change Engine Coolant

■

Replace Radiator Hoses

■

Note: During the first 50 hours of operation, avoid long periods of no load or sustained maximum load operation. If the light tower is to run for longer than five minutes without a load, shut the engine down.

The engine is supplied with engine break-in oil from the factory . Extra care during the first 50 hours of engine operation will result in better performance and longer engine life. DO NOT exceed 50 hours of operation with the break-in oil. Operate the engine at lighter loads (50-75% of maximum) as much as possible. If the engine has spent significant time at idle, constant speeds and/or light load or if makeup oil is required, a longer break in period may be needed. Consult the engine OPERA TION AND MAINTENANCE MANUAL for a full description of necessary procedures on the addition of break-in oil and extension of the break-in period.

The periodic maintenance schedule below lists basic maintenance intervals for the engine. For detailed maintenance procedures refer to the engine operators manual. A copy of this manual was supplied with the unit when it was shipped from the factory. For additional or replacement copies of the engine operators manual, contact an authorized engine dealer in your area.

* Drain daily in humid or rainy conditions.

** Change the engine oil and filter after the first 50 hours of operation, then every 250 hours.

OPTIONAL LOWER RADIATOR HOSE HEATER USE AND MAINTENANCE

The following points should be followed when operating a unit equipped with a lower radiator hose heater .

Improper use of the lower radiator hose heater could result in serious personal injury .

• Ensure cooling system is full of proper mixture of water and engine coolant before each heater use.

• Heater is designed for all-night operation; however, 2-5 hours of heating just prior to st arting is usually sufficient

for proper engine starting.

• When heater is in operation, unit must be parked in a level position to maintain the proper orientation of the

heater.

• Use only an undamaged extension cord, outdoors rated, three-prong grounded 120V AC cord with a minimum

amperage rating of 10A. Connect to properly grounded 120V AC, GFCI outlet only .

• Unplug extension cord from power first; then unplug heater cordset from extension cord before starting the

engine.

WARNING

Page 36

DERATING FOR ALTITUDE

All light towers are subject to derating for altitude and temperature; this will reduce the available power for operating to tools and accessories connected to the auxiliary outlets. T ypical reductions in performance are 2-4% for every

1000 ft. (305 meters) of elevation and 1% per 10º F (3-5º C) increase in ambient air temperature over 72º F (22.2º C).

TROUBLESHOOTING SHUTDOWN CONDITIONS

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 20 psi. 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 within five (5) seconds.

4. Check the oil pressure sender on the engine block and the connecting wiring for damage. To check for continuity

between the sender and the engine controller, remove the bolts at the top and center of the control p anel and open the panel like a door. Consult the DC wiring diagrams in this manual for the proper p ath between the engine controller and the pressure sender.

5. If the oil level, pressure sender and wiring are good, the oil loss may be caused by engine failure. Consult the

ENGINE OPERA TION AND MAINTENANCE MANUAL for additional information on excessive oil consumption.

HIGH COOLANT TEMPERA TURE SHUTDOWN

1. Check the coolant level in the overflow jug.

2. Restart the engine and read the coolant temperature to verify High Coolant Temperature Shutdown. Stop the

engine immediately if the coolant temperature is 230°F 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 small access panel located on top of the generator enclosure directly above the radiator. Add coolant until it is 3/4” below the filler neck. Replace the radiator cap and access panel.

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. Check the coolant temperature sender on the engine block and the connecting wiring for damage. To check for

continuity between the sender and the engine controller, remove the bolts around the control p anel and slowly drop panel down. Consult the DC wiring diagrams in this manual for the proper path between the engine controller and the pressure sender.

8. If the sender and wiring are good and no other problems are found, restart the engine. Observe the coolant

temperature and shut the engine down immediately if it starts to overheat.

9. Reduce the load on the generator and restart the engine. Observe the coolant temperature and shut theengine

down immediately if it starts to overheat. Consult the ENGINE OPERA TION AND MAINTENANCE MANUAL for additional information on engine overheating.

OVERCRANK SHUTDOWN

1. Check the fuel level in tank.

2. Check for proper operation of the fuel pump.

3. Check air filter for blockage.

4. If the engine will not start, consult the ENGINE OPERA TION AND MAINTENANCE MANUAL for additional

information on troubleshooting starting problems.

OVERSPEED OR UNDERSPEED SHUTDOWN

1. Disconnect all loads and restart the generator . Read the frequency (Hz) on the LCD display . With no loads on

the generator, the frequency should read 60.0 Hz.

2. If the frequency is above or below 60.0 Hz, the engine speed will have to be adjusted. See the ENGINE OP-

ERA TION AND MAINTENANCE MANUAL for throttle adjustment s on mechanically governed units and see the ELECTRONIC GOVERNOR MANUAL for electronically controlled units.

Page 37

TROUBLESHOOTING THE LIGHTS

DANGER

HIGH VOLTAGE! 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 OFF BUT BALLAST INDICAT ORS ON CONTROL P ANEL ARE ON:

1. Mast light is too hot. Allow light to cool 10-15 minu tes before restarting.

2. Faulty bulb connection. Check that the bulb is tight in the socket.

3. Bulb broken. Check for broken arc tube or outer bulb jacket, broken or loose components in bulb envelope or blackening/deposits inside tube.

4. Check the connections inside the mast junction box and each mast light housing/socket.

5. Check the mast electrical cord for damage and check the cord connections inside the control box.

MAST LIGHTS OFF AND BALLAST INDICA TORS ON CONTROL P ANEL ARE OFF:

1. Check the connections inside the control box and inside each ballast box.

2. Generator output incorrect. Check the incoming voltage to the ballast by checking the available voltage on the duplex receptacle. Incoming voltage should be 120V +/- 5V . If volt age is incorrect engine speed may need to be adjusted or generator may require service. Contact Magnum Products Technical Service Department for more information.

3. Low transformer output. The voltage from the transformer should read approximately 400 V AC as the light “strikes” (induces an arc), then drop and slowly rise back up to stabilize at 240-260 V AC. 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 lights and ground. If proper voltage is not achieved, perform capacitor check to determine if the capacitor or coil needs to be replaced.

MAST LIGHTS ON BUT THE LIGHT OUTPUT IS LOW:

1. Fixture or lens dirty . Clean reflective surface inside fixture and both inside and outside surface of glass lens.

2. Bulb worn. Replace bulb due to normal use.

3. Check the mast coil cord, mast junction box and mast light connections.

4. Generator output incorrect. Check the incoming voltage to the ballast. Incoming voltage should be 120V +/- 5V . If voltage is incorrect engine speed may need to be adjusted or generator may require service.

5. Low transformer output. Perform transformer check as described above.

If problems persist, contact Magnum Products Technical Service for assistance.

MAST LIGHT CONNECTIONS

Page 38

UNIT DECALS

AERIENS PEUT PROVOQUER DE SERIEUSES

BLESSURES ET MEME LA MORT. NE POSITIONNEZ

PAS LE MAT DECLAIRAGE SOUS DES CABLES

ELECTRIQUES AERIENS.

EL CONTACTO CON CABLES ELECTRICOS DE

TENDIDO AEREO CONDUCIRA A GRAVES HERIDAS O

MUERTE. NUNCA UBIQUE LA TORRE DE LUZ DEBAJO

DE CABLES ELECTRICOS DE TENDIDO AEREO.

TOUT CONTACT AVEC DES CABLES ELECTRIQUES

DANGER

CONTACT WITH OVERHEAD ELECTRICAL POWER

LINES WILL CAUSE SERIOUS INJURY OR DEATH.

DO NOT POSITION LIGHT TOWER UNDER ELECTRICAL

POWER LINES.

KONTAKT MIT OBERIRDISCHEN STROM

FREILEITUNGEN KANN ZU SCHWEREN VERLETZUNGEN

ODER TOD FÜHREN. NIEMALS BELEUTUNGSTURM

UNTER ELEKTRISCHEN LEITUNGEN AUFSTELLEN.

PELIGRO

GEFAHR

DANGER

COMPLETELY LOWER TOWER BEFORE TILTING MAST.

TILTING AN EXTENDED MAST COULD CAUSE SERIOUS

INJURY OR DEATH.

VOR DEM EINSCHWENKEN DES MASTES,

BELEUCHTUNGSTURM GANZ NIEDERLASSEN.

EINSCHWENKUNG DES VERLÄNGERTEN MASTES KANN

SCHWERE VERLETZUNG ODER TOD HERVORRUFEN.

BAJE EL MASTIL COMPLETAMENTE ANTES DE

VOLCARLO A LA POSICION HORIZONTAL. EL VOLCAR UN

MASTIL EXTENDIDO PUEDE LLEGAR A CAUSAR GRAVES

HERIDAS O MUERTE.

RABAISSEZ COMPLETEMENT LE MAT AVANT DE LE

BASCULER. LE GASCULEMENT D’UN MAT DEPLOYE

PEUT PROVOQUER DE SERIEUSES BLESSURES ET MEME

LA MORT.

DANGER

PELIGRO

DANGER

GEFAHR

Located on

Manual Holder

DANGER

GEFAHR PELIGRO DANGER

Located on Control Box

A NON-SECURED, FALLING MAST WILL CAUSE SERIOUS INJURY OR DEATH IF A PERSON IS HIT. TO SECURE MAST, INSERT THE LOCK BAR INTO MAST MOUNTED BRACKET THEN INSERT PIN.

EIN UNGESICHERTER HERABFALLENDER MAST KANN SCHWERE, ODER VERLETZUNGEN VERURSACHEN, WENN ER AUF EINE PERSON FÄLLT. ZUM SICHERN DES MASTES DIE VERRIEGELUNGSSTANGE IN DIE MASTMONTIERTE HALTERUNG STECKEN UND DANN DEN SICHERUNGSSTIFT EINSTECKEN.

UN MASTIL INCORRECTAMENTE FIJADO PODRIA CAUSAR LESIONES SEVERAS O MUERTE AL CAER SOBRE UNA PERSONA. PARA FIJAR EL MASTIL, INTRODUZCA PRIMERO EL PERNO DE BLOQUEO DENTRO DE LA PIEZA DE FIJACION DEL MASTIL Y LUEGO COLOQUE EL PASADOR DE SEGURIDAD.

LA CHUTE D’UN MAT MAL FIXE SUR UNE PERSONNE PEUT ENTRAINER DES BLESSURES GRAVES OU LA MORT. POUR FIXER SOLIDEMENT LE MAT, INSEREZ LA BARRE DE VERROUILLAGE DANS LE SUPPORT DU MAT, PUIS INSEREZ LA BROCHE.

DANGER

GEFAHR

PELIGRO

DANGER

WARNING

SECURE MAST IN TRANSPORT LOCK BEFORE LIFTING OR TOWING!

WARNUNG

DEN MAST VOR DEM ANHEBEN ODER ABSCHLEPPEN IN DER TRANSPORTHALTERUNG SICHERN!

ADVERTENCIA

FIJE EL MASTIL EN LA TRABA DE TRANSPORTE ANTES DE REMOLCAR O LEVANTAR EL MISMO.

ADVERTISSEMENT

VERROUILLEZ SOLIDEMENT LE MAT POUR LE TRANSPORT AVANT DE LE HISSER OU DE LE REMORQUER.

Inside, Back Panel

DANGER GEFAHR PELIGRO DANGER

WARNING

WARNUNG

ADVERTENCIA

ADVERTISSEMENT

WARNING

ITEM NO. PART NO. QTY DESCRIPTION

1 12141 1 Decal set, LT eng/safety 4-lang 2 12140 1 Decal set, common mast 4-lang 3 12142 2 Decal, ground 4 16488 1 Decal, Magnum logo with red stripe 5 12191 1 Decal, label set - MLG25

WARNUNG

ADVERTENCIA

ADVERTISSEMENT

WARNING

GENERATOR CAN AUTOMATICALLY START WHICH CAN CAUSE SERIOUS INJURY. DISCONNECT BATTERY BEFORE SERVICING.

WARNUNG

AGGREGAT KANN AUTOMATISCH STARTEN UND KÖRPERLICHE VERLETZUNG VERURSACHEN. VOR SERVICEARBEIT BATTERIE ABKLEMMEN.

ADVERTENCIA

GENERADOR PUEDE ARRANCAR AUTOMATICAMENTE Y CAUSAR LESIONES PERSONALES. DESCONECTE LA BATERIA ANTES DE PRESTAR SERVICIO.

AVERTISSEMENT

GENERATEUR PUET DEMARRER AUTOMATIQUEMENT RESULTANT EN DES ACCIDENTS DE PERSONNE. DECONNECTER BATTERIE AVANT

TOUT ENTRETIEN.

Page 39

DIESEL

UNIT DECALS

WARNING

SECURE MAST IN TRANSPORT LOCK BEFORE LIFTING OR TOWING!

WARNUNG

DEN MAST VOR DEM ANHEBEN ODER ABSCHLEPPEN IN DER TRANSPORTHALTERUNG SICHERN!

ADVERTENCIA

FIJE EL MASTIL EN LA TRABA DE TRANSPORTE ANTES DE REMOLCAR O LEVANTAR EL MISMO.

ADVERTISSEMENT

VERROUILLEZ SOLIDEMENT LE MAT POUR LE TRANSPORT AVANT DE LE HISSER OU DE LE REMORQUER.

WARNING

WARNUNG

ADVERTENCIA

ADVERTISSEMENT

DANGER

DIESEL

GEFAHR PELIGRO DANGER

Inside, Front Panel

WARNING

WARNUNG

ADVERTENCIA

ADVERTISSEMENT

WARNING

WARNUNG

ADVERTENCIA

ADVERTISSEMENT

WARNING

WARNUNG

ADVERTENCIA

ADVERTISSEMENT

WARNING

WARNUNG

ADVERTENCIA

ADVERTISSEMENT

ITEM NO. PART NO. QTY DESCRIPTION

1 12141 1 Decal set, LT eng/safety 4-lang 2 12140 1 Decal set, common mast 4-lang

Page 40

UNIT DECALS

www.m-p-llc.com

WARNING

STAND CLEAR OF FRONT AND REAR OF MACHINE WHEN MAST IS BEING TILTED UP OR DOWN.

WARNUNG

AUFENTHALT INVORDERER ODER HINTERER UMGEBUNG DES GERÄTES VERMEIDEN WÄHREND MAST HOCH ODER NIEDER GESCHWENKT WIRD.

ADVERTENCIA

MANTENGASE ALEJADO DE LA PARTE DELANTERA O TRASERA DE LA MAQUINA MIENTRAS QUE SE ESTA PROCEDIENDO A LEVANTAR EL MASTIL A LA POSICION VERTICAL O VOLCARLO A LA POSICION HORIZONTAL.

ADVERTISSEMENT

TENEZ-VOUS A DISTANCE DE L’AVANT ET DE L’ARRIERE DE LA MACHINE PENDANT LE BASCULEMENT DU MAT DANS UN SENS OU DANS L’AUTRE.

WARNING

WARNUNG

ADVERTENCIA

ADVERTISSEMENT

DANGER

DO NOT SET UP UNIT IN HIGH WIND OR DURING ELECTRICAL STORMS! CHECK FOR OVERHEAD OBSTRUCTIONS BEFORE USING!

GEFHAR

STELLEN SIE NICHT MASSEINHEIT IM STARKEN WIND ODER WÄHREND DER ELEKTRISCHEN STÜRME AUF! ÜBERPRÜFEN SIE AUF OBENLIEGENDE HINDERNISSE, BEVOR SIE VERWENDEN!

PELIGRO

¡CNO INSTALE LA UNIDAD EN FUERTE VIENTO O DURANTE TORMENTAS ELÉCTRICAS! ¡CCOMPRUEBE PARA SABER SI HAY OBSTRUCCIONES DE ARRIBA ANTES DE USAR!

DANGER

N'INSTALLEZ PAS L'UNITÉ EN FORT VENT OU PENDANT LES ORAGES ÉLECTRIQUES ! VÉRIFIEZ LES OBSTRUCTIONS AÉRIENNES AVANT UTILISATION !

DANGER

DO NOT MOVE UNIT WITH TOWER UP! UNIT MUST BE MOVED WITH MAST DOWN AND SECURE IN CRADLE!

GEFHAR

BEWEGEN SIE EINHEIT MIT DEM TURM NICHT! EINHEIT KANN NUR MIT DEM MAST BEWEGT WERDEN UNTEN UND GESICHERT IN DER WIEGE!

PELIGRO

¡NO MUEVA UNIDAD CON TORRE! UNIDAD PUEDE SER SÓLO MOVIDA CON MÁSTIL ¡ABAJO Y ASEGURADO EN CUNA!

DANGER

NE BOUGEZ PAS D'UNITÉ AVEC LA TOUR EN HAUT! L'UNITÉ PEUT SEULEMENT ÊTRE BOUGÉE AVEC LE MÂT EN BAS ET PROTÉGÉ DANS LE BERCEAU!

ALWAYS KEEP TENSION ON CABLES! SLACK MAY CAUSE CABLE DAMAGE AND EXCESSIVE WEAR!

IMMER UNTERHALT-SPANNUNG AUF KABELN! LOCKERE MAI URSACHE CABLEDAMAGE UND ÜBERMÄSSIGE ABNUTZUNG!

¡CSIEMPRE TENSIÓN DE LA SUBSISTENCIA EN LOS CABLES! ¡CCAUSA FLOJA CABLEDAMAGE DE MAYO Y DESGASTE EXCESIVO!

TOUJOURS TENSION DE SUBSISTANCE SUR DES CÂBLES ! CAUSE LÂCHE CABLEDAMAGE DE MAI ET USAGE EXCESSIF !

MAST CONTROL

MAST-STEUERUNG

5 5

CONTROL DEL MÁSTIL COMMANDE DE MÂT

TO VERTICAL

TO HORIZONTAL

Located on

Electric Winches

MAST TELESCOPE

TELESCOPE UP

TELESCOPE DOWN

MAST-TELESKOP

MAST TELESCOPE

TÉLESCOPE DE MÂT

Located on

inside of mast

junction box.

GEFAHR

DANGER

PELIGRO

DANGER

DO NOT REMOVE!

GEFAHR

ENTFERNEN SIE NICHT!

PELIGRO

NO QUITE!

DANGER

N'ENLEVEZ PAS !

WARNUNG

This decal is also

located on the

bottom side of mast

WARNING

ADVERTENCIA

ADVERTISSEMENT

WARNING

WARNUNG

ADVERTENCIA

ADVERTISSEMENT

STAND CLEAR OF FRONT AND REAR OF MACHINE

WHEN MAST IS BEING TILTED UP OR DOWN.

MANTENGASE ALEJADO DE LA PARTE DELANTERA O

TRASERA DE LA MAQUINA MIENTRAS QUE SE ESTA

PROCEDIENDO A LEVANTAR EL MASTIL A LA POSICION

VERTICAL O VOLCARLO A LA POSICION HORIZONTAL.

TENEZ-VOUS A DISTANCE DE L’AVANT ET DE

L’ARRIERE DE LA MACHINE PENDANT LE BASCULEMENT

DU MAT DANS UN SENS OU DANS L’AUTRE.

AUFENTHALT INVORDERER ODER HINTERER UMGEBUNG

DES GERÄTES VERMEIDEN WÄHREND MAST HOCH ODER

NIEDER GESCHWENKT WIRD.

6. VERIFIER LES LAMPES DE LA REMORQUE.

5. ATTACHER LA CHAINE DE REMORQUAGE AU VEHICULE. UTILISANT UNE METHODE CROISEE.

4. ATTACHER LES CHAINES DE SURETE EN VEHICULE TRACTEUR.

3. ATTACHER LA REMORQUE FERMEMENT AU VEHICULE DU VEHICULE TRACTEUR. AU DEBIT NOMINAL DU POIDS BRUT DE

2. UTILISER UN CROCHET D’ATTELAGE CONFORME

1. LIRE LA NOTICE D’EMPLOI.

INSTRUCTIONS DE REMORQUAGE

6. CONTROLE LAS LUCES DEL REMOLQUE. LA CADENA DE DESPRENDIMIENTO.

5. FIJE EN EL VEHICULO DE REMOLQUE

4. FIJE EN CRUZ LAS CADENAS DE SEGURIDAD. REMOLQUE AL VEHICULO DE REMOLQUE.

3. ASEGURESE DE ACOPLAR CORRECTAMENTE EL BRUTO" DEL VEHICULO DE REMOLQUE CLASIFICADO PARA LA "CLASE DE PESO

2. UTILICE UN ACOPLE CORRECTAMENTE

1. LEA EL MANUAL DEL OPERARIO.

6. ANHÄNGERLEUCHTEN PRÜFEN.

5. ABREISSKETTE AM FAHRZEUG ANBRINGEN.

4. SICHERHEITSKETTEN KREUZWEISE ANBRINGEN. BEFESTIGEN.

3. ANHÄNGER SICHER AM ZUGFAHRZEUG ENTSPRICHT . DIE DER GESAMTBETRIEBSGEWICHTSKLASSE

2. ANHÄNGEVORRICHTUNG VERWENDEN,

1. BETRIEBSVORSCHRIFT LESEN.

ABSCHLEPPINSTRUKTIONEN

6. CHECK TRAILER LIGHTS.

5. ATTACH BREAKDOWN CHAIN TO VEHICLE. PATTERN.

4. ATTACH SAFETY CHAINS USING A CROSS

3. SECURELY ATTACH TRAILER TO TOW VEHICLE. "GROSS VEHICLE WEIGHT RATING".

2. USE HITCH RATER FOR TRAILER'S

1. READ OPERATOR'S MANUAL.

TOWING INSTRUCTIONS INSTRUCCIONES DE REMOLQUE

ITEM NO. PART NO. QTY DESCRIPTION

1 12141 1 Decal set, LT eng/safety 4-lang 2 12140 1 Decal set, common mast 4-lang 3 11275 1 Decal, Magnum logo w/web, red vinyl 4 12262 1 Decal, 4000/5000 set up 4-lang (manual winch) 5 12880 1 Decal, instruction 4000/5000 4-lang (electric winch) 6 13614 1 Decal, mast junction box wiring - 4 light

Page 41

UNIT DECALS

ENGINE START

ENGINE STOP

OPERATING INSTRUCTIONS

BEFORE STARTING

1. READ OPERATOR'S MANUAL.

2. LEVEL UNIT.

3. BLOCK WHEELS.

4. GROUND UNIT.

5. CHECK ALL FLUID LEVELS.

MANUAL STARTING

1. DISCONNECT ALL EXTERNAL LOADS.

2. SET VOLTAGE SELECTOR SWITCH.

3. LOCK VOLTAGE SELECTOR SWITCH.

4. TURN EMERGENCY STOP BUTTON TO "ON" POSITION.

5. PUSH ENGINE START SWITCH TO"START/RUN" POSITION.

6. ENGINE WILL MAKE 3 ATTEMPTS TO START.

REMOTE START

1. SEE OPERATOR'S MANUAL.

STOPPING

1. DISCONNECT ALL EXTERNAL LOADS.

2. PUSH ENGINE START SWITCH TO "OFF" POSITION.

3. FILL FUEL TANK.

INSTRUCCIONES PARA LA PUESTA EN MARCHA

ANTES DEL ARRANQUE

1. LEA EL MANUAL DEL OPERARIO.

2. NIVELE LA UNIDAD.

3. COLOQUE CUÑAS DEBAJO DE LAS RUEDAS.

4. CONECTE LA UNIDAD A TIERRA.

5. CONTROLE TODOS LOS LIQUIDOS.

ARRANQUE MANUAL

1. DESCONECTE TODAS LAS CARGAS EXTERNAS.

2. AJUSTE LA LLAVE SELECTORA DE VOLTAJE.

3. BLOQUEE LA LLAVE SELECTORA DE VOLTAJE.

4. GIRE A LA POSICION “ON” EL BOTON DE PARADA DE EMERGENCIA.

5. OPRIMA A LA POSICION “ARRANQUE/MARCHA” EL INTERRUPTOR DE ARRANQUE DEL MOTOR.

6. EL MOTOR INTENTARA ARRANCAR 3 VECES.

ARRANQUE REMOTO

1. VEA EL MANUAL DEL OPERARIO.

DETENCION DEL MOTOR

1. DESCONECTE TODAS LAS CARGAS EXTERNAS.

2. OPRIMA A LA POSICION “OFF” EL INTERRUPTOR DE ARRANQUE DEL MOTOR.

3. LLENE EL TANQUE DE COMBUSTIBLE.

BETRIEBSANLEITUNG

VOR DEM STARTEN

1. BETRIEBSVORSCHRIFT LESEN

2. GERÄT WAAGRECHT STELLEN.

3. RÄDER BLOCKIEREN.

4. GERÄT ERDEN

5. STAND ALLER FLÜSSIGKEITEN PRÜFEN.

HANDSTARTEN

1. ALLE ÄUSSEREN BELASTUNGEN ABSCHALTEN.

2. SPANNUNGSWAHLSCHALTER SETZEN.

3. SPANNUNGSWAHLSCHALTER VERRIEGELN.

4. NOTSTOPKNOPF IN “ON” POSITION SETZEN.

5. MOTORSTARTSCHALTER AUF POSITION “START/LAUF” DRÜCKEN.

6. MOTOR VOLLZIEHT 3 STARTVERSUCHE.

FERNSTART

1. SIEHE BETRIEBSVORSCHRIFT.

ABSCHALTEN

1. ALLE ÄUSSEREN BELASTUNGEN ABSCHALTEN.

2. MOTORSTARTSCHALTER AUF POSITION “OFF” DRÜCKEN.

3. KRAFTSTOFFTANK FÜLLEN.

INSTRUCTIONS D'OPERATION

AVANT LE DEMARRAGE

1. LIRE LA NOTICE D’EMPLOI.

2. NIVELER LA MACHINE.

3. BLOQUER LES ROUES AVEC CALES DE ROUES.

4. METTRE A TERRE LA MACHINE.

5. VERIFIER LE NIVEAU DE TOUS LES FLUIDES.

DEMARRAGE A LA MAIN

1. DECONNECTER TOUS LES REGIMES EXTERNES

2. REGLER LE COMMUTATEUR DES TENSIONS D'ALIMENTATION.

3. SERRER LE COMMUTATEUR DES TENSIONS D'ALIMENTATION.

4. TOURNER LE BOUTON D’ARRET D’URGENCE A LA POSITION “ON”.

5. PRESSER L’INTERRUPTEUR DE DEMARRAGE DU MOTEUR A LA POSITION “DEMARRAGE/MARCHE”.

6. LE MOTEUR S’ESSAYERA DE DEMARRER 3 FOIS.

DEMARRAGE A DISTANCE

1. LIRE LA NOTICE D’EMPLOI.

ARRET

1. DECONNECTER TOUS LES REGIMES EXTERNES.

2. PRESSER L’INTERRUPTEUR DE DEMARRAGE DUMOTEUR A LA POSTION “OFF”.

3. REMPLIR LE RESERVOIR A CARBURANT.

GENERATOR

NEUTRAL BONDED TO FRAME

NULL-LEITER AM RAHMEN ANGESCHLOSSEN CONDUCTOR NEUTRO CONECTADO AL CHASIS

CONDUCTEUR NEUTRE MIS A LA MASSE DU CHASSIS

MAIN

CIRCUIT

BREAKER

LIGHTS AND EQUIPMENT

OUTLETS

MAIN

CIRCUIT

BREAKER

1 2

STARTING THE GENERATOR

DAS STARTEN DES GENERATORS

COMIENZO DEL GENERADOR

COMMENCEMENT DU GÉNÉRATEUR

1. TURN CONTROL SWITCH “ON”

CONTROL

OFF

2. PUSH “ENGINE START”

ENGINE START

STOPPING THE GENERATOR

DAS AUFHÖREN DES GENERATORS

PARADA DEL GENERADOR

ARRÊT DU GÉNÉRATEUR

1. PUSH “ENGINE STOP”

ENGINE STOP

2. TURN CONTROL SWITCH “OFF”

CONTROL

OFF

DANGER GEFAHR PELIGRO DANGER

Located on inside of lug door:

DANGER

IMPROPER CONNECTION OF GENERATOR TO A BUILDING’S ELECTRICAL SYSTEM CAN ALLOW ELECTRICAL CURRENT FROM THE GENERATOR TO BACKFEED INTO UTILITY LINES. THIS MAY RESULT IN ELECTROCUTION OF UTILITY WORKERS, FIRE OR EXPLOSION. CONNECTIONS TO A BUILDING’S ELECTRICAL SYSTEM MUST BE MADE BY A QUALIFIED ELECTRICIAN AND COMPLY WITH ALL APPLICABLE LAWS AND ELECTRICAL CODES.

GEFAHR

UNFACHGEMAESSER ANSCHLUSS DES STROMAGGREGATES AN DEN GEGAEUDE-STROMNETZANSCHLUSS KANN ZU GEGENSTROM VOM AGGREGAT IN DAS STROMNETZ FUEHREN. DIES KOENNTE ZU STROMSCHLAG, FEUER ODER EXPLOSION FUEHREN. ANSCHLUSS AN EIN GEBAEUDESTROMNETZ MUSS VON QUALIFIZIERTEM PERSONAL DURCHGEFUEHRT WERDEN UND MIT ALLEN ZUTREFFENDEN GESETZEN UND ELEKTRIZITAETS-VORSCHRIFTEN UEBEREINSTIMMEN.

PELIGRO

LA CONEXION INCORRECTA DE UN GENERADOR AL SISTEMA ELECTRICO DE UN EDIFICIO PUEDE CONDUCIR A UN RETORNO DE LA CORRIENTE ELECTRICA DESDE EL GENERADOR AL SISTEMA DE DISTRIBUICION ELECTRICO PUBLICO. ESTO PUEDE CONDUCIR A LA ELECTROCUCION DE LOS OBREROS DEL SERVICIO PUBLICO, INCENDIOS O EXPLOSIONES. SOLO UN TECNICO ELECTRICISTA CAPACITADO PODRA EFECTUAR LA CONEXION AL SISTEMA ELECTRICO DEL EDIFICIO. LA CONEXION ELECTRICA A DEBERA CUMPLIR CON LAS LEYES Y CODIGOS ELECTRICOS PERTINENTES.

DANGER

LE BRANCHEMENT NON CONFORME DU GENERATEUR AU RESEAU DE DISTRIBUTION ELECTRIQUE D’UN IMMEUBLE PEUT PROVOQUER LA REINJECTION DU COURANT ELECTRIQUE DU GENERATEUR DANS LES LIGNES DU RESEAU PUBLIC. CECI PEUT PROVOQUER UNE ELECTROCUTION DES EMPLOYES DU SERVICE PUBLIC, UN INCENDIE OU UNE EXPLOSION. LES BRANCHEMENTS AU RESEAU ELECTRIQUE. IMMEUBLE DOIVENT ETRE EFFECTUES PAR UN ELECTRICIEN QUALIFIE ET DOIVENT ETRE CONFORMES A TOUTES LES LOIS OU TOUS LES CODES ELECTRIQUES APPLICABLES.

2 2 2 2

TERMINAL CONNECTIONS / VERBINDUNGSKLEMMEN / BORNES DE CONEXION / RACCORDS TERMINALS

T10

T11

T12

L1-L2 = 480V L1-N = 277V L2-L3 = 480V L2-N = 277V L3-L1 = 480V L3-N = 277V N-

208 120

480 277

L-N

T12

T10

T12

T11

L-N

L1-L2 = 208V L1-N = 120V L2-L3 = 208V L2-N = 120V L3-L1 = 208V L3-N = 120V N-

L-L

L1-L3 = 240V L2-N = -----L1-N = 120V L3-N = 120V

L-L

240 120

T11

T10

T4 T1

120V120V

240V

Located on inside of outlet panel:

PUSH TO RESET

ZUR RÜCKSTELLUND DRÜCKEN

EMPUJE PARA REAJUSTAR POUSSER POUR RÉARMER

3 54

ITEM NO. PART NO. QTY DESCRIPTION

1 13136 1 Decal set, MLT4250 2 12191 1 Decal, label set - MLG25 3 22960 -- Decal, breaker 20 Amp 4 23203 -- Decal, breaker 30 Amp 5 23204 -- Decal, breaker 50 Amp

2 2 2 2

Page 42

MANUAL WINCH MAST ASSEMBLY

Page 43

ITEM NO. PART NO. QTY DESCRIPTION

1 1 1954 1 Coil cord, mast 2 16600 2 Winch, manual 3 60584 2 Nut, .750-10 nylock G5 yellow zinc 4 1 1902B 1 Weldment, mast tube 5 1 1649Z 1 Weldment, t-bolt 6 15292 1 Screw , .750-10X6.500 hx hd SS 7 15380 4 Pin, cotter - .125X1.250 8 14262 2 Sheave, 3 in.

9 60247 1 Washer , flat .750 10 14234 2 Pin, clevis .500 x 2.00 1 1 14798 1 Cable, .188 in. X 16 ft. steel w/teardrop 12 14151 1 Cable, .188 in. X 1 1 f t. steel w/ball swedge 13 15003 1 Thimble, cable - .188 14 15002 2 Clip, wire rope .188 15 1 1933B 1 Weldment, mast - 4.00 16 14439 1 Strain relief - .50 NPT, .50 cord, water tight 17 15015 3 Pin, clevis .500 x 1.25 18 15014 4 Shim, 2 x 3 x .281 GSM 19 15013 4 Shim, 2 x 2 x .344 GSM 20 16143 5 Clamp, tubing .500 21 1 1934B 1 Weldment, mast - 3.00 22 16257B 1 Weldment, mast - 2.00 23 12095B 1 Bracket, junction box 24 15829 1 Reflector, red 25 13527B 1 Weldment, mast crossbar (3/4” studs) 26 15006 1 Cable - .188 in. X 27 ft. galv steel w/swedge 27 60397 1 Screw, 10-32X1.000 pan hd phil 28 60252 2 Washer, split lock #10 29 60237 2 Washer, flat #10 30 14231 2 Nut, 10-32 hx 31 60744 2 Washer, flat .750ID/1.25OD/.06th delrin 32 15623 2 Winch handle, 9.00 in long

OPTIONAL FEA TURES:

33 15612 1 Cable, 16-7 cold mast drape 34 13869B 2 Weldment, light storage (RH oval light) 35 13870B 2 Weldment, light storage (LH oval light)

15006

14151

14798

Page 44

ELECTRIC WINCH MAST ASSEMBLY

Page 45

ITEM NO. PART NO. QTY DESCRIPTION

1 1 1954 1 Coil cord 2 12875B 2 Cover, winch contactor 3 1 1293 2 Contactor, electric winch - warn 4 65049 2 Relay, 12V 30/40A N.O. w/diode 5 65707 2 Switch, toggle - SPDT spring weatherproof 6 12872B 2 Bracket, winch mounting 7 12874 2 Winch, electric - 770 lb. hoist 8 15380 5 Pin, cotter - .125X1.250

9 15006 1 Cable, .188 in. x 27 ft. w/ball swedge 10 14262 3 Sheave, 3 in. 1 1 15014 4 Shim, 2 x 3 x .281 GSM 12 15015 3 Pin, clevis .500 x 1.25 13 65510B 1 Bracket, sensor mtg 14 6551 1 2 Sensor, proximity 15 14439 1 Strain relief- .50 NPT , .50 cord 16 12085B 1 Weldment, 4.00 mast - Electric Winch 17 1 1967B 1 Channel, electric winch mount 18 16143 2 Clamp, tubing .500 19 60584 2 Nut, .750-10 nylock G5 yellow zinc 20 60247 1 Washer, flat .750 21 14234 2 Pin, clevis .500 x 2.00 22 12876B 1 Weldment, mast tube - Electric Winch 23 15292 1 Screw, 750-10 x 6.50 hx hd SS 24 1 1649Z 1 Weldment, t-bolt 25 14798 1 Cable - .188 in. X 16 ft. steel w/teardrop 26 14151 1 Cable - .188 in. X 11 ft. steel w/swedge 27 15003 1 Thimble, cable - .188 28 15002 2 Clip, wire rope - .188 single saddle 29 15013 4 Shim, 2 x 2 x .344 GSM 30 12084B 1 Weldment, 3.00 mast 31 12095 1 Bracket, junction box 32 15829 1 Reflector, red 33 13527B 1 Weldment, mast crossbar (3/4” studs) 34 60397 1 Screw, 10-32X1.000 pan hd phil 35 60252 2 Washer, split lock #10 36 60237 2 Washer, flat #10 37 14231 2 Nut, 10-32 hx 38 16257B 1 Weldment, mast - 2” 39 60744 2 Washer, flat .750ID/1.25OD/.06th delrin 40 12922 4 Boot, battery cable - red

OPTIONAL FEA TURES:

41 13869B 2 Weldment, light storage 42 13870B 2 Weldment, light storage 43 15612 1 Cable, 16-7 cold mast drape

Page 46

FRAME AND COMPONENTS

6, 69

32 29

41 40 39

14, 70

Page 47

ITEM NO. PART NO. QTY DESCRIPTION

1 16270 1 Fitting, .375MNPT to .250 FNPT straight 2 16271 1 Fitting, 90-.250NPTX.188 barb 3 15142 1 Fitting, strt-.250NPTX.312 barb 4 12259 1 Fuel pick up tube - 24.00 in. 5 12361B 1 Weldment, fuel tank strap 6 12080 1 Cap, fuel tank - vented, 3.5 dia. grn diesel only 7 12162 1 Tank, fuel - 56 gallon poly 8 11735B 1 Weldment, fuel tank strap

9 12120B 1 Panel, fuel tank support 10 11681 1 Jack, sidewind - 2000lb 11 14326 4 Ring, retaining 12 13335B 1 Weldment, chassis 13 14682 1 Bracket, battery hold-down 14 60820 2 Bolt, J - .250-20 X 9.00 15 14145 1 Battery tray 16 61143 16 Nut, .250-20 U-clip G5 PO short type 17 13301 4 Assy, transformer - can and base 18 12408Z 2 Weldment, outrigger 19 11682 3 Jack, top wind - 2000lb 20 60096 10 Nut, .500-20 wheel lug 21 15540 2 Wheel, ST205/75R15, 1820# - 6 PR 22 13131 1 Axle, 3000 lb 58TC 45SC 23 11279 8 Axle nut (Ubolt) 24 11278 2 Tie plate 25 60503 6 Screw, .562-18 hx shackle GR5 26 19637 4 Plate, shackle bracket 27 60504 6 Nut, .562-18 hx shackle lock 28 11277 4 U-bolt 29 60674 10 Stud, wheel 30 70056 2 Bearing seal 31 11276 2 Hub w/races 32 11511 2 Roller bearing 33 70055 2 Bearing L44643 34 12309 2 D-washer 35 12310 2 Tang washer 36 12308 2 Spindle nut 37 70053 2 Dust cap 38 70054 2 Rubber plug 39 60393 16 Screw, .250-20X1.000 hx hd G5 40 60696 16 Washer, .250 flat .625/.050 SS USS 41 60704 16 Washer, .250 split lock SS 42 14324 2 Kit, plunger 43 15015 1 Pin, clevis - .500 DIA X 1.250 44 14261 1 Sheave - 2 in. 45 15380 2 Pin, cotter - .125X1.250 46 14845B 1 Spring, kickback - 50 lb. 47 11554Z 1 Spacer plate - kick-back spring 48 11057B 1 Weldment, mast post 49 14275 1 Spring - 2.75 50 14663Z 1 Bar, latch 51 14403 1 Pin, cotterless - .312 X 1.000

60707 1 Chain, sash - no 8 stainless steel 60706 1 Ring, split - 1.00 SS

52 15165 1 Pin, roll - .250X1.250 plain

Continued on next page.

Page 48

ITEM NO. PART NO. QTY DESCRIPTION

53 16830 1 Coupler - 2.00 ball/2.50 channel 54 23367 1 Chain, safety - 7,800 lbs. rated 55 12420B 1 Weldment, removable tongue 56 13300 4 Cam, transformer - ballast box (5.5” height) 57 13299 4 Transf. & base brkt w/str relief-60Hz MH cyl bal

OPTIONAL FEATURES:

58 12235B 1 Weldment, spare tire holder 59 11368B 1 Weldment, tongue - adjustable hitch w/storage 60 19335B 1 Hitch, pintle eye (adj) - 3.00 ID 61 19518 1 Coupler, adjustable - 2 in. ball 61 11672B 1 Weldment, hitch - 3.00X1.625 ring/2.50 tube 62 16741B 1 Weldment, combo hitch-2.50 tongue removable 64 16835B 1 Weldment, lunette ring - 3.00 ID/2.5 tongue 65 16999B 1 Weldment, lunette ring - 2.50 ID/2.50 tongue 66 23254 3 Jack, 3000# top wind - tube mounted 67 11965Z 4 Weldment, jack adapter 68 11978 1 Jack, 2000# side wind - tube mounted 69 12137 1 Cap, fuel tank - vent 3.5 dia grn 70 60984 2 Bolt, J- .250-20 X 7.00 (for gel cell battery option) 71 23505 4 Cable, pin tether 12" 72 23256 4 Pin, jack - 2000# tube mtd

OPTIONAL FEATURES

For Containment/Silent Pack:

73 10496B 1 Weldment, chassis - 60 gal containment 74 11952 1 Valve, drain - 20X1.5MM thread/barb 75 60777 1 Clamp, hose - .312 fuel hose crimp style 76 50051 1 ft. Hose, fuel - .375 ID 50 PSI SAE 30R7 77 61157 1 Fitting, 90 - .375 barb X .750MNPT br 78 60498 1 Fitting, plug-.750NPT square drive

To engine

oil drain.

Page 49

GENERATOR ASSEMBLY

ITEM NO. PART NO. QTY DESCRIPTION

1 60165 8 Screw, M8-1.25X16 std hex G10.9 LB 2 60166 16 Washer, M8 flat ZB DIN125 hardened TP200 3 11000 1 Plate, drive - SAE 7.5 4 11975B 2 Plate, gen adapter 5 11524 2 Compression mount, engine 6 60275 2 Screw, .500-13X1.000 hx hd G5 7 60702 2 Washer, .500 split lock SS 8 60065 4 Screw, M12-1.75X40 sflg hex G10.8 LB

9 60204 4 Washer, .500 split lock lb hvy 10 60013 4 Nut, M12-1.75 hex G8.8 LB DIN934 11 22899 1 Generator, 282NSL1505

Note: Engine and generator parts used in all Magnum Products LLC equipment carry the Original Equipment Manufacturer (OEM) warranty unless otherwise stated. OEM warranty parts must be purchased through an OEM dealer. Please contact Magnum Products LLC with questions.

Page 50

MAST JUNCTION BOX ASSEMBLY - HARD WIRED LIGHTS

ITEM NO. PART NO. QTY DESCRIPTION

1 12109 1 Box cover, 2-gang plastic 2 66100 4 Connector, 2 pos. Wago 3 66101 2 Connector, 3 pos. Wago 4 66102 1 Connector, 5 pos. Wago 5 60755 2 Fitting, .750MNPT x .500FNPT nylon 6 15864 4 Strain relief, .500NPT water tight 7 12095B 1 Bracket, junction box 8 16143 1 Clamp, tubing .500

9 12094 1 Box, junction 10 14656 1 Strain relief, .750NPT water tight 11 60424 4 Screw, 6-32X.750 pan phil G2 ZC self threading 12 13749 1 Gasket, junction box - HFI 281000

- 11789 - Assembly, mast junction box

Page 51

MAST JUNCTION BOX ASSEMBLY - QUICK DISCONNECT LIGHTS

ITEM NO. PART NO. QTY DESCRIPTION

1 12109 1 Box cover, 2-gang plastic

2 66100 4 Connector, 2 pos. Wago

3 66101 2 Connector, 3 pos. Wago

4 66102 1 Connector, 5 pos. Wago

5 60755 2 Fitting, .750MNPT x .500FNPT nylon

6 15403 4 Connector, quick disconnect (female)

7 15404 4 Cap, receptacle w/chain

8 12095B 1 Bracket, junction box

9 16143 1 Clamp, tubing .500 10 12094 1 Box, junction 11 14656 1 Strain relief, .750NPT water tight 12 12713 1 Fitting, adapter-1/2"-14 male to 1/2"-14 female 13 60424 4 Screw, 6-32X.750 pan phil G2 ZC self threading 14 13749 1 Gasket, junction box - HFI 281000

- 11957 - Assembly, mast junction box

Page 52

ENCLOSURE ASSEMBLY

Page 53

ITEM NO. PART NO. QTY DESCRIPTION

1 25333W 1 Panel, back access 2 12195 1 Gasket, radiator access plate 3 11381 2 Fender, plastic 4 11507W 1 Panel, right side sheetmetal 5 16591W 2 Panel, door 6 16598 2 Hinge, door 7 10284W 1 Panel, roof w/access hole 8 10287W 1 Panel, rear 4000 Isuzu 9 10220 2 Light, rear tail/turn - no grommet

10 10221 2 Grommet, rear light rubber 4.5

10219 2 Assembly, rear tail/turn light (9 & 10) 11 10224 1 Bracket, license plate 12 10225 1 Light, license bracket

10223 1 Assembly, license plate light (11 & 12) 13 11222 1 Bracket, manual holder 14 11121 1 Holder, manual black tube 15 15123 2 Latch, paddle 16 15215 6 Bumper, rubber 17 65406 2 Light, clearance marker red 18 22550 1 Switch, Estop, 2NO/1NC 19 65407 2 Light, clearance marker amber 20 12257W 1 Panel, left side sheetmetal 21 12605 2 Door latch SS - T-style 22 11886B 1 Bracket, control box 23 12012W 1 Panel, front sheetmetal 24 11724 2 Foam, door

- 10222 - Plug, rear light 3-wire MLT (not shown)

- 10226 - Plug, 2-wire license light (not shown)

OPTIONAL FEATURES

For Containment/Silent Pack:

25 13101W 1 Duct, radiator guard 26 16469W 2 Duct, front 27 12754W 1 Panel, front 4000 containment 28 16739W 1 Panel, door - U bolt lock

Page 54

AUXILIARY OUTLET PANEL ASSEMBLY

Page 55

ITEM NO. PART NO. QTY DESCRIPTION

1 65535 1 Clamp, 90° 3/4" 2 screw 2 12248B 1 Weldment, outlet cover 3 10081 1 Hinge, continuous - 11.00 in. 4 11484B 1 Cover, breaker 5 14130 2 Receptacle, 120V/20A GFCI 6 65530 2 Block, terminal - 2 pole lug type, 7 pos./pole 7 14137 2 Receptacle, 240V/30A twist lock 8 18089 2 Receptacle, 120/ 240V 50A twist lock

9 12246B 1 Weldment, outlet panel 10 15215 2 Rubber bumper 11 11485B 1 Angle, mounting support 12 65492 2 Breaker, 50A, 250V, 2 pole aux contact 13 65851 2 Breaker, 30A, 250V, 2 pole, screw term w/ aux 14 65849 2 Breaker, 20A, 120V, 1-pole, push button 15 15849 1 Cover, receptacle - weather proof 16 65467 2 Cover, receptacle 50A twist lock 17 65460 2 Cover, 20/30A 240V twist lock

18 18992

-- 12398 1 Receptacle panel (2x5-20R, 2xL6-30R, 2x50A)

1 Stud, ground

Page 56

AUXILIARY OUTLET PANEL OPTIONS

PART NUMBER 12399

Receptacle Panel (2x5-20R, 3xL6-30R, 1x50A)

PART NUMBER 12402

Receptacle Panel (2x5-20R, 3xL6-20R, 1x50A)

PART NUMBER 12400

Receptacle Panel (2x5-20R, 3xL14-30R, 1x50A)

PART NUMBER 12401

Receptacle Panel (2x5-20R, 4xL14-30R)

Page 57

PART NUMBER 13540

Receptacle Panel (2x5-20R, 1xTT-30R, 1xL6-30R, 2x50A)

PART NUMBER 13893

Receptacle Panel (2x5-20R, 2xTT-30R, 2x14 - 50)

1 2 3 4

7 8 9

ITEM NO. PART NO. QTY DESCRIPTION

1 14130 2 Receptacle, 120V 20A GFCI

2 14137 - Receptacle, 240V 30A twist lock

3 18089 - Receptacle, 125/250V 50A twist lock

4 65488 - Receptacle, 240V 30A twist lock

5 65849 2 Breaker, 20A, 120V, 1 pole, push button

6 65851 2 Breaker, 30A 250V 2 pole (JA) screw term, w/aux

7 65492 - Breaker, 50A 250V 2 pole aux contact

8 65489 1 Receptacle, 120V/30A (TT-30R) (RV)

9 65520 1 Cover, receptacle - weather proof 50A 3-wire 10 65815 - Receptacle, 240V/50A (14-50R) (RV)

Page 58

OV AL LIGHT ASSEMBLY

26 27

Page 59

ITEM NO. PART NO. QTY DESCRIPTION

1 60304 1 Screw, M5 x 25 pan hd phillips 2 60447 1 Nut, M5 nylock 3 13367 1 Assembly, aluminum ring 4 13369 1 Lens, glass oval 5 13373 1 Gasket, lens oval 6 1 1391 1 Bulb, 1000W MH short length 7 13399 2 Screw, M4 x 18 pan hd phillips 8 60067 4 Washer, #10 flat .435/.060 SS

9 13370 1 Assembly, tether 10 13372 2 Washer, #4 nylon 1 1 60051 2 Nut, M4 nylock 12 13376 1 Bracket, socket end plate 13 13388 10 Screw, M5 x 12 slotted hex w/flange 14 13377 1 Bracket, end plate 15 13366 1 Housing 16 60307 2 Nut, 500-13 nylk G5 ZC 17 60309 2 Washer, .500 flat 1.060/.090 ZC SAE 18 13392 2 Stud, trunnion 19 13390 4 Washer, nylon (for part number 13392) 20 13374 1 Support, housing/trunnion 21 13378 2 Gasket, silicone 22 13393 2 Screw, M5 x 12 phillips green 23 13381 1 Socket, bulb 24 13375 1 Support, housing/trunnion 25 15861 1 Nut, special, .500 NPT lock (LN101SC) 26 13386 1 Fitting, nipple 27 13387 1 Connector, weather tight 28 15864 1 Strain relief, .50 NPT watertight .270/.464 ID 29 13892 1 Support, bulb - oval light 30 13403 1 Handle, T - oval light (wing nut) 31 13438 1 Cord, power hard wired 32 13368 1 Trunnion, oval light

-- 13311 4 Assembly , light fixture - 1000Whard wired oval

OPTIONAL FEA TURES:

33 13383 1 Cord, power quick disconnect 34 19041 1 Clip, spring holder 35 60398 1 Screw, 10-32X.500 pan phil18-8 ss 36 60061 1 Nut, 10-32 nylk G5

-- 13601 4 Assy, light fixture/quick disconnect cord clip

Page 60

ENGINE COOLING ASSEMBLY

LOWER RADIATOR HOSE

Page 61

ITEM NO. PART NO. QTY DESCRIPTION

1 60034 12 Screw, .375-16X.750 hx ser flg 2 60206 12 Washer, split lock .375 3 60386 1 Washer, flat .375 4 26305 1 Radiator, aluminum 5 11626B 1 Weldment, fan shroud 6 15422 4 Clamp, hose SAE 20 7 11760B 1 Panel, fan guard - right 8 60115 8 Screw, M6X1.0X12 hx ser flg

9 11769B 1 Weldment, fan guard - left 10 11596B 1 Strut, radiator support 11 60144 1 Nut, .250-20 nylock 12 22419B 1 Bracket, support overflow jug .5 gal. 13 19726 1 Clamp, overflow bottle 14 60047 1 Nut, M6 hx lock class 6 DIN985 15 19714 1 Cap, overflow bottle 16 60014 1 Screw, M6X1.0X35 hx GR8.8 DIN933 17 60135 1 Screw, M6X1.0X20 hx ser flg 18 20287 1 Jug, overflow 2 qt. (.5 gal.) 19 14216 1 Clamp, hose SAE 04 20 19220 1 Hose, overflow 21 12064 1 Hose, radiator upper 22 12356 1 Hose, radiator lower

OPTIONAL FEATURES

23 65650 1 Heater, engine - low rad hose 1.5"

Page 62

ENGINE ASSEMBLY

Page 63

ITEM NO. PART NO. QTY DESCRIPTION

1 21505 1 Assembly, air filter

2 60009 4 Screw, M8X1.25X25 hx ser flg

3 12990B 1 Bracket, air filter

4 60018 14 Screw, M10X1.25X20 hx ser flg

5 60316 2 Clamp, hose - SAE 32

6 60342 4 Nut, M8X1.25 hx GR8.8 SS

7 22320 1 Hose, air filter

8 21937 1 Element, air filter - 12” filter

9 12421B 1 Weldment, exhaust flange 10 25455 2 Clamp, 1.5” muffler 11 12608 1 Muffler 12 12606B 3 Bracket, muffler 13 12612B 1 Heat shield 14 12683B 1 Pipe, exhaust 15 12634B 1 Bracket, muffler mounting 16 12635B 1 Bracket, muffler support 17 11471B 2 Weldment, engine mount 18 11524 2 Compression mount, 4.38x4.00x1.50 19 18105 1 Sensor, magnetic pick-up 20 23899 1 Dipstick, oil, Isuzu 4LE 21 19258 1 Fan, 15.75 in. 22 22258 1 Belt, fan - 4LE1 23 19247 1 Sensor, temperature (small) 24 19232 1 Fitting, .125NPTF X .125-28 BSP male 25 18106 1 Sensor, oil pressure 26 21674 1 Engine, Isuzu 4LE1NYGV-01, with #5 SAE BH 27 15074 1 Cable, battery - 4 AWG X 38 in. red 28 15073 1 Cable, battery - 4 AWG X 25 in. blk .38 lug 29 19042 1 Strap, braided ground - 10 in. 30 15183 1 Filter, oil - Isuzu (3LB,3LD,4LE) 31 15331 1 Fuel filter element 32 15372 1 Solenoid, fuel shutdown 33 16205 1 Pump, fuel - Isuzu 4LE1 34 11040 1 Isuzu, plug, oil pan 35 11041 1 Isuzu, oil plug gasket

-- 26049 1 Alternator (not shown)

-- 26033 1 Starter assembly (not shown)

OPTIONAL FEATURES:

36 11952 1 Valve, drain - 20X1.5MM thread/barb 37 50051 .25 ft. Hose, fuel - .375 ID 50 PSI SAE 30R7 38 60777 1 Clamp, hose - .312 fuel hose crimp style

For Containment/Silent Pack Option:

-- 26306 1 Fan, 15.75 in. increasing arc (not shown)

Page 64

CONTROL PANEL ASSEMBLY

3 6

9 10

Page 65

ITEM NO. PART NO. QTY DESCRIPTION

1 60160 3 Screw, M8X1.25X30 hx ser flg

2 65287 3 Lug, terminal single #6-350 MCM

3 12065 1 Channel, glastic

4 12066 2 Angle, glastic

5 13126W 1 Panel, control

6 11811W 2 Bracket, glastic plate

7 60020 7 Nut, M8 hx ser flg lock

8 60062 3 Screw, 10-32X.750 pan hd phil

9 60044 2 Screw, M5X0.8X12 pan hd phil 10 60738 2 Nut, 10-32 speed u-type 11 25077 1 Switch, toggle - SPST 20A VAC 12 18113 1 Potentiometer, 2.5K 2 watt 13 60057 4 Nut, M4 hx hd 14 60084 2 Washer, flat M4 15 12632 2 Switch, trigger safety, N.O. & N.C. 16 18496 1 Bushing, 2.50 x 2.00 ID 17 60038 4 Nut, M5 HX nylock 18 60355 2 Screw, M4X25 pan hd phil 19 18890 1 Terminal block, 2-pos 20 19163 1 Bushing, .500 x .375 ID 21 66186 1 Controller, eng/gen - programmed 22 18614 1 Lug, terminal dual #6-250MCM 2 hole 23 60009 3 Screw, M8X1.25X25 hx ser flg 24 19227 4 Bushing, .812 OD x .625 ID 25 60058 8 Washer, #6 split lock 26 60190 8 Screw, 6-32X.312 pan phil 27 65325 4 Light, indicator - green w/ wire 28 14249 4 Breaker, 15A 250V 1pole

- 18934 1 Guard, potentiometer (not shown)

- 12628 1 Assembly, control panel (complete)

Page 66

CONTROL BOX ASSEMBLY

Page 67

ITEM NO. PART NO. QTY DESCRIPTION

1 12694W 1 Panel, top control box

2 65619 1 Breaker, 90A, 3 pole

3 65429 1 Breaker, 100A, 250V, 2 pole

4 18556 1 Regulator, voltage - SE 350

5 60355 6 Screw, M4X35 pan head phil

6 65442 3 Transformer, current - 200:5A

7 60115 25 Screw, M6X1.0X12 hx ser flg

8 18081 2 Relay, ignition solenoid (12V-65 A)

9 60036 14 Nut, M6 hx ser flg lock 10 60051 13 Nut, M4 hx nylock 11 60061 6 Nut, 10-32 hx nylock 12 60023 11 Insert, threaded M6 13 11764B 1 Bracket, phase switch 14 60091 4 Screw, M4X12 pan hd phil 15 65456 1 Switch, phase - 63A, 3-pos (Y,y,Z) 16 60044 4 Screw, M5X0.8X12 pan hd phil 17 65590 1 Block, terminal - 12 pos. lug type 18 60045 3 Screw, M4X35 pan hd phil 19 65481 1 Block, terminal - 6 pos. 20 18598 1 Hinge, controller panel - 18.75 21 14203 1 Block, terminal 10 pos. 22 60062 2 Screw, 10-32X.750 pan hd phil 23 14204 1 Kit, ground bar 24 60190 10 Screw, 6-32X.312 pan hd phil 25 13137W 1 Weldment, control box 26 13343B 1 Bracket, dual cap mount 27 60168 2 Screw, .312-18X.750 hx hd G5 28 60095 2 Nut, .312-18 ser flg G5 case hard 29 65959 2 Capacitor, dual 24 uF sealed stud mount 30 60098 2 Nut, .500-13 ser flg G5 31 66013 1 Terminal block, 14 pos. 32 24925B 2 Spacer, .50 OD .344 ID 1.00 long, black 33 60159 2 Screw, M4-0.70X45 pan phil G4.8

- 12625 1 Assembly, control box enclosure

- 12624 1 Assembly, control box (complete)

OPTIONAL FEATURES:

34 12021B 1 Bracket, control box roof (optional) 35 65498 1 Switch, disconnect (optional) 36 11947 1 Light, interior with switch (optional)

Page 68

LUG DOOR ASSEMBLY

ITEM NO. PART NO. QTY DESCRIPTION

1 18598 1 Hinge, controller panel - 18.75

2 60156 8 Screw, M5X0.8X16 pan hd phil

3 60038 4 Nut, M5 hx nylock DIN985

4 20762 1 Lock, door - 1/4 turn cam

5 12631W 1 Panel, lug door

6 15215 1 Bumper, rubber

7 18893 1 Handle, lug door

8 60043 2 Washer, split lock M5 DIN127

9 60068 2 Screw, 10-24X.500 pan phil

-- 12630 1 Assembly, lug door

Page 69

TRAILER LIGHTS WIRING DIAGRAM

ITEM NO. PART NO. QTY DESCRIPTION

1 10264 1 Harness, left side trailer 2 10261 1 Harness, main trailer 4000 3 10265 1 Harness, right side trailer

- 65465 - Adapter, trailer wiring flat 4 to rnd 7 blade

- 65464 - Adapter, trailer wiring flat 4 to rnd 7 pin

- 65463 - Adapter, trailer wiring flat 4 to rnd 6 pin

Page 70

AC WIRING DIAGRAM

GFCI

RECPT

120V

RECPT

GFCI

BRKER

120V

RED

BLUE

BLACK

CORD

MAST POWER

YELLOW

WHITE

GREEN

BROWN

120V

BRKER

GRN/YEL 14GA

PAN EL

RECEPTACLE

GRN/YEL 14GA

GRN/YEL 10GA

LT BLU 14GA

LT BLU 10GA

240V

BRN 14GA

BLK

240V

BLK 10GA

LT BLU 10GA

8/4 SOOW CABLE

RCPT.

BLK

BREAKER

BLK 10GA

240V

BLK

240V

BREAKER

BLK 10GA

RCPT.

BLK

BLK 10GA

240V

BLK

240V

BLK 10GA

RCPT.

BLK

BREAKER

BLK 10GA

RCPT.

240V

BLK

240V

BREAKER

BLK 10GA

CAPCAP

RED

BLK/YEL

TRANSFORMER

RED

BLK/YEL

TRANSFORMER

RED

MAST POWER CORD

BLK/YEL

TRANSFORMER

YEL

RED

YEL

RED

BLU

GRY

RED

WHT

BLU

WHT

BRN

BLK

101112

BLK

BLU

GRY

BLK

RED

BLK/YEL

34567

YEL

T3T4T5T6T7

GROUND

GENERATOR

FRAME

F-

F+

F-

T11

T10

T12

GRN

NEUTRAL TO GROUND

CIRCUIT

BREAKER

SHUNT 12VDC

6GA

MECHANICAL LUGS

6GA

L2 L3

6GA

WHT

BLK

456

BONDING JUMPER

RED

QUICK CONNECTED TO

WIRES (DASHED)

ON PHASE SWITCH

(3) JUMPER

10GA

VOLTAGE REGULATOR

CIRCUIT

BREAKER

LIGHT SW 4

LIGHT SW 1

LIGHT SW 3

LIGHT SW 2

T6T8T10

T11T7T1

T12

10 14

CT-3

CT-2CT-1

PAIR BLK 10GA

Page 71

DC WIRING DIAGRAM

BRN/WHT

F+

RED F+

F-

BLK FWHT

7 6

BLK

SE350

BRN 50HZ 60HZ

VOLTAGE REGULATOR

WHT

GRN

SHUNT

LUG DOOR

BR/WT

RED

GRY

YL/GN

WHT BLK

VIO

CUT BACK SHEILD

AND TAPE

BLK

YEL

BLK

RED

BLU

RED

BLK

WT/VI

RED ORG

1NC

GRY

WT/BU

FUEL

SOLENOID

SHUTDOWN

RED

BLK

WHT

2NC

BLK

4NO

90215, ORG 8.07.08

3NO

4NO

FUEL

PUMP

SHIELD

OIL SENDER

"OPTION"

BLU

ALTERNATOR

WHT

BLK

BRN

AUX

BRN

BREAKER

L1 L2

YL/GN

BLK

GRN

BLK

WHT

BLK

WHT

BLK

RED BLK

RED

TRIP

RED

ORG

BRN

YEL

ORG

RED

WHT WHT WHT

ORG

YEL

VIO

YEL

BLU

GRY

VIO

YL/GN

ORG

WHT

RED

BLK

VIO

BLK

GRY

WT/BU

YEL

WT/VI

BLK

RED

BLU

WHT

BLK

RPM IN

GRY

RPM GND

WT/BU

AI1

FUSE

15 AMP

WHT

YEL

BLK

C+

YEL

B+

RELAY

STARTER

GLOW

RELAY

YEL

WT/VI

AI2

AI3

YEL

BLU

RED

GRY

BLK

RED

BLK

RED

C+

YEL

B+

RED

WHT

YEL

L1 L2 L3

YEL

WHT

BRN

ORG

YEL

GN/YL

ORG

BRN

COM

REMOTE START

GRN

ORG

GRY

ORG

BLU

BI1

BI5

BI6

BI2

BI3

B14

RED

POWER

CONTROL

RED

BLK

RED

YEL

VIO

GRY

BI7

LOCATION

C1 (+12VDC)

C2 (+12VDC)

BO1 (START)

BO3

BO2 (FUEL

BO7

BO6

BO4

BO5

OPTIONAL

BATTERY

DISCONNECT

2 PIN PLUG (RPM)

3 PIN ANALOG INPUTS

PLUG LOCATION

BOTTOM

MDC CONTROLLER

BOTTOM

OIL IN

LARGE 4 PIN GENERATOR VOLTAGE

FUEL IN

WATER IN

NEUTRAL

PLUG LOCATION

TOP

PLUG LOCATION

SMALL 4 PIN GENERATOR CURRENT

RELAY BOARD

TOP

CT NEUTRAL

7 PIN PLUG (BINARY INPUTS)

PLUG LOCATION

TOP

REMOTE START

LOW COOLANT OPTION

OPEN

BOTTOM

PLUG LOCATION PIN

D+

POWER + DC

POWER - DC

OPEN

PREHEAT

FUE

SRT

BO2

BO1

Page 72

AC WIRING PANEL OPTIONS

PART NUMBER 12399; Receptacle Panel (2x5-20R, 3xL6-30R, 1x50A)

(TO GROUND)

(TO NEUTRAL)

(TO GROUND)

(TO NEUTRAL)

(TO MAIN

BREAKER)

(TO MAIN

BREAKER)

PART NUMBER 12402; Receptacle Panel (2x5-20R, 3xL6-20R, 1x50A)

PART NUMBER 12400; Receptacle Panel (2x5-20R, 3xL14-30R, 1x50A)

(TO GROUND)

(TO NEUTRAL)

(TO MAIN

BREAKER)

Page 73

AC WIRING PANEL OPTIONS

PART NUMBER 12401; Receptacle Panel (2x5-20R, 4xL14-30R)

(TO GROUND)

(TO NEUTRAL)

(TO GROUND)

(TO NEUTRAL)

(TO MAIN

BREAKER)

(TO MAIN

BREAKER)

CIRCUIT

BREAKER

30 AMP

120 VOLT

30 AMP

RECEPTACLE

CIRCUIT

BREAKER

30 AMP

240 VOLT

30 AMP TWIST LOCK RECEPTACLE

CIRCUIT

BREAKER

50 AMP

240 VOLT

50 AMP TWIST LOCK RECEPTACLE

CIRCUIT

BREAKER

50 AMP

240 VOLT

50 AMP TWIST LOCK RECEPTACLE

PART NUMBER 13540; Receptacle Panel (2x5-20R, 1xTT-30R, 1xL6-30R, 2x50A)

(TO MAIN

(TO GROUND)

(TO NEUTRAL)

RECEPTACLE

CIRCUIT

BREAKER

30 AMP

120 VOLT

30 AMP

BREAKER)

CIRCUIT

BREAKER

30 AMP

240 VOLT

30 AMP TWIST LOCK RECEPTACLE

CIRCUIT

BREAKER

50 AMP

240 VOLT

50 AMP

RECEPTACLE

CIRCUIT

BREAKER

50 AMP

240 VOLT

50 AMP

RECEPTACLE

PART NUMBER 13893; Receptacle Panel (2x5-20R, 2xTT-30R, 2x14-50)

Page 74

DC CIRCUIT WIRING DIAGRAM, DUAL ELECTRIC WINCH

ELECTRIC WINCH (OPTIONAL)

RED

BRN

COM

BLK

WHT

PROX. AUX RELAY

N/O

87A

N/C

BLK

PROX SWITCH

TILT

RED

WINCH

RED

VIO

8586

BLK

BLU

RED

BLU

RED

BLK

RED

BRN

BLK

BRN

WHT

PROX. AUX RELAY

COM

BLK

PROX SWITCH

N/O

87A

N/C

EXTEND

YEL

BLK

BLU

WINCH

RED

BLK

50 AMP

CIRCUIT

BATTERY 12V

BREAKERS

BLK

Page 75

MAST JUNCTION BOX WIRING DIAGRAM

Page 76

REV: B P ART NO: 13134

11.07.08

Magnum MLT 4250 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual