Magnum MLT 4250 User manual

OPERATING/PARTS MANUAL
MLT 4250

2
INTRODUCTION
Thismanualprovidesinformationandprocedurestosafelyoperateandmaintainthelighttowerandgenerator. For
yourownsafety and protection from physical injury, carefully read,understand,andobservethesafetyinstructions
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.
MagnumProductsLLCrecommendsthatatrainedandlicensedprofessionalperformallelectricalwiringandtesting
functions. Any wiring should be in compliance with the United States National Electric Code (NEC), state and local
codesandOccupationalSafetyandHealthAssociation(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
shipmentfrom the factory. The manual provides detailedoperation and maintenance procedures for the engine.
Additionalcopies of the engine operators manualareavailablefromthe engine manufacturer.
MAGNUM PRODUCTS LLC
215 Power Drive • Berlin, WI 54923
U.S.A.
Phone: [phone]
Fax: [phone]
Toll Free: 1-800-926-9768
www.m-p-llc.com
CALIFORNIAPROPOSITION65 WARNING:
Diesel engine exhaust and some of its constituents are known to the state
of California to cause cancer, birth defects and other reproductive harm.
WARNING
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.
To ORDER SERVICE PARTS, please contact the dealer from which your purchased the unit,
or call Magnum Products to locate a dealer in your area.
EngineMake:
EngineSerial Number:
EngineModelNumber:
GeneratorMake:
GeneratorModelNumber:
GeneratorSerialNumber:
UnitModelNumber:
UnitSerialNumber:

TABLE OF CONTENTS Page
INTRODUCTION .................................................................................................................2
TABLEOFCONTENTS ......................................................................................................3
SAFETYNOTES................................................................................................................4
OPERATINGSAFETY........................................................................................................4
ENGINESAFETY ..............................................................................................................5
SERVICESAFETY ............................................................................................................5
TOWINGSAFETY..............................................................................................................6
REPORTINGTRAILERSAFETY DEFECTS .......................................................................6
UNITSERIALNUMBERLOCATIONS .................................................................................6
SAFETYSYMBOL SUMMARY..........................................................................................7
SPECIFICATIONS ........................................................................................................ 8 - 9
EXTERIORLOCATIONS ...................................................................................................10
MAINCONTROLPANELCOMPONENTS ........................................................................ 11
MAGNUMDIGITALCONTROLLER(MDC) ................................................................ 12 - 13
GENERATORMONITORING ............................................................................................13
ENGINEMONITORING ............................................................................................ 14 - 15
FINEVOLTAGEADJUSTMENT ....................................................................................... 15
MDCCONTROLLERINFORMATIONDISPLAYS,FUNCTIONSANDRESET....................16
MDCCONTROLLER- GENERATOROPERATIONALSTATUS.........................................16
MDCCONTROLLER-ALARMMANAGEMENT ...............................................................16
MDCCONTROLLERLISTOFPOSSIBLEALARMSWITHDESCRIPTIONS..............17 - 18
MDCCONTROLLER-HISTORY ......................................................................................18
ADJUSTINGTHEDISPLAYBACKLIGHTING....................................................................19
RESETTINGTHE“TIME TOSERVICE” REMINDER.........................................................19
GENERATOROUTPUTCONNECTIONLUGS ..................................................................20
VOLTAGESELECTORSWITCH ......................................................................................21
AUXILIARYOUTLETS ......................................................................................................22
VOLTAGEREGULATION..................................................................................................22
EMERGENCYSTOP SWITCH ........................................................................................ 22
MAINCIRCUITBREAKER................................................................................................23
REMOTESTARTTERMINALBLOCK...............................................................................23
TRANSFERSWITCH ................................................................................................23 - 24
LIGHTTOWERSET-UP ...................................................................................................25
RAISINGTHETOWER.....................................................................................................26
RAISINGTHETOWER WITHOPTIONAL ELECTRICWINCH...........................................27
LIGHTTOWERSTARTUP ...............................................................................................28
PRE-STARTCHECKLIST .................................................................................................28
MANUALSTARTINGOFTHEGENERATOR .............................................................28 - 30
AUTO(REMOTE)STARTINGOFTHEGENERATOR .......................................................30
LIGHTOPERATION..........................................................................................................31
SHUTTINGDOWNTHEGENERATOR .............................................................................31
LOWERING THETOWER ................................................................................................32
LOWERINGTHETOWER WITHOPTIONAL ELECTRICWINCH......................................32
REMOVINGTHELIGHTSFORTRANSPORTATION.........................................................33
TOWINGTHETRAILER ...................................................................................................33
TRAILERWHEEL BEARINGS .........................................................................................33
LIFTINGTHETRAILER.....................................................................................................34
GENERALMAINTENANCE..............................................................................................34
ENGINEMAINTENANCE .................................................................................................35
OPTIONALLOWERRADIATORHOSE HEATER USEAND MAINTENANCE ...................35
DERATINGFORALTITUDE ..............................................................................................36
TROUBLESHOOTINGSHUTDOWNCONDITIONS ...........................................................36
TROUBLESHOOTINGTHELIGHTS .................................................................................37
UNITDECALS...........................................................................................................38 - 41
MANUALWINCHMASTASSEMBLY........................................................................42 - 43
ELECTRICWINCH MASTASSEMBLY......................................................................44 - 45
FRAMEANDCOMPONENTS ...................................................................................46 - 48
GENERATORASSEMBLY ...............................................................................................49
MASTJUNCTIONBOXASSEMBLY-HARD WIREDLIGHTS...........................................50
MASTJUNCTION BOXASSEMBLY-QUICKDISCONNECTLIGHTS...............................51
ENCLOSUREASSEMBLY ........................................................................................52 - 53
AUXILIARYOUTLETPANELASSEMBLY..................................................................54 - 55
AUXILIARYOUTLETPANELOPTIONS .....................................................................56 - 57
LIGHTASSEMBLY ....................................................................................................58 - 59
ENGINECOOLINGASSEMBLY................................................................................60 - 61
ENGINEASSEMBLY ................................................................................................62 - 63
CONTROLPANELASSEMBLY.................................................................................64 - 65
CONTROLBOXASSEMBLY .....................................................................................66 - 67
LUGDOORASSEMBLY ..................................................................................................68
WIRINGDIAGRAMS .................................................................................................69 - 75 3

4
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.
ThismanualcontainsDANGERS,WARNINGS,CAUTIONS,NOTICESandNOTESwhichmustbe
followedtopreventthepossibilityofimproperservice,damagetotheequipment,personalinjury ordeath.
Thefollowing formattingoptionswill applywhencalling the readersattentionto theDANGERS,WARN-
INGS,CAUTIONS,NOTICESandNOTES.
SAFETY NOTES
NOTICE
Indicatesahazardoussituationwhich,ifnotavoided,
mayresult inpropertyorequipment damage.
Note: Notescontain additionalinformationimportant to aprocedureand will befoundwithin theregular
text body of this manual.
DANGER
INDICATESAHAZARDOUSSITUATIONWHICH,IFNOTAVOIDED,
WILLRESULTINDEATHORSERIOUSINJURY.
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.
OPERATING SAFETY
Before using the light tower be sure you read and understand all of the instructions! This equipment was
designedforspecificapplications;DONOTmodifyorusethisequipmentforanyapplicationotherthanwhich
itwasdesignedfor. Equipmentoperatedimproperlyorbyuntrainedpersonnelcanbedangerous! Readthe
operatinginstructionsandfamiliarizeyourselfwiththelocationandproperuseofallinstrumentsandcontrols.
Inexperiencedoperatorsshouldreceiveinstructionfromsomeonefamiliarwiththeequipmentbeforebeing
allowed to operate or set up the light tower. The following points should be practiced at all times:
•Thearea immediatelysurroundingthelight towershouldbedry, clean,andfreeof debris.
•Positionandoperatethelight tower on a firm, level surface.
• NEVER startaunit in need of repair.
•Lower tower when not in use, or if high winds or electrical storms are expected in the area.
•Makecertain light tower is well grounded and securely fastenedtoagoodearthenground.
•Thetower extends up to 30 ft. (9m). Make sure area above trailer is open and clear of overhead wires
andobstructions.
•Bulbs become extremely hot in use! Allow bulb and light fixture to cool 10-15 minutes before han-
dling.
•Keepareabehindtrailerclearofpeoplewhileraisingandloweringmast!
• NEVER raise,lower or turn mast while unitisoperating!
•Trailermustbeleveledandoutriggersextendedbeforeraisingtower. Outriggersmustremainex-
tendedwhile tower is up.
•Iffor any reason any part of mast hangs up or winch cable develops slack while raising or lowering
tower,STOPimmediately! Contactanauthorizedservicerepresentative.
• NEVER removesafety pin or pull mast locking pin while tower is up!
• NEVER use tower if insulation on electrical cord is cut or worn through.
• NEVER operatelights without protective lens cover in place or with a lens cover that is cracked or
damaged!

5
Internalcombustionenginespresentspecialhazardsduringoperationandfueling! Failuretofollowthe
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
ventilationequipment.
• DO NOT fill fuel tank near an open flame, while smoking, or while engine is running. DO NOT fill tank
inanenclosedareawithpoorventilation.
• 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.
• DONOT removeenginecoolant cap whileengineis hot.
• DO NOT operate the unit without a functional exhaust system. Prolonged exposure to sound levels in
excessof85 DBA can cause permanent hearing loss. Wear hearingprotectionwhen working around
arunningengine.
•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,burnfleshor eat holes in clothing. Protective eye wear andclothingarenecessary when
working on or around the battery. Always disconnect the NEGATIVE (-) battery cable from the
correspondingterminalbeforeperforminganyserviceontheengineorothercomponents.
• Shuttheenginedownifany of the following conditions exist during operation:
1. Noticeablechange in engine speed.
2. Loss of electrical output.
3. Equipmentconnected to the generatoroverheats.
4. Sparkingoccurs.
5. Enginemisfires or there isexcessiveengine/generatorvibration.
6. Operatingon a combustible surface.
7. Protectivecovers are loose or missing.
8. Ifthe ambient air temperature is above110°F.
ENGINE SAFETY
This unit uses high voltage circuits capable of causing serious injury or death. Only a qualified electrician
shouldtroubleshootorrepairelectricalproblemsoccurringin thisequipment.
•Before servicing light tower, make sure the engine start switch is turned to OFF, circuit breakers are
open(off)andthenegativeterminalonthebatteryisdisconnected.NEVERperformevenroutine
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
theengine and generator foranymoistureand dry the unitbeforeuse.
• NEVER washthe unitwithapower washer orhighpressure hose.
•Openmaincircuitbreaker beforedisconnectingbatterycables.
•Keephands,feet,andlooseclothingawayfrommovingpartsongeneratorandengine.
•Make sure slings, chains, hooks, ramps, jacks, and other types of lifting devices are attached
securelyandhaveenoughweight-bearing capacity to lift or hold the equipment safely. Always
remainawareofthepositionofotherpeoplearoundyouwhenliftingtheequipment.
SERVICE SAFETY

6
Towinga trailer requires care! Both thetrailer and vehicle must be in good condition and securely fas-
tened to each other to reduce the possibility of an accident. Also, some states require that large trailers
beregistered and licensed. Contact your localDepartment of Transportation office to check on license
requirementsforyourparticularunit.
•Check that the hitch and coupling on the towing vehicle are rated equal to, or greater than, the trailer's
"grossvehicleweightrating"(GVWR).
• Checktires on trailer for tread wear, inflation, and condition.
•Inspectthe hitchandcoupling forwearor damage. DO NOT tow trailerusingdefective parts!
•Make sure the trailer hitch and the coupling are compatible. Make sure the coupling is securely
fastenedtothevehicle.
•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.
•Makesuredirectionalandbrakelightsonthetrailerareconnectedandworkingproperly.
•Check that all lug nuts holding wheels on are tight and that none are missing.
•Maximumrecommendedspeedforhighwaytowingis45m.p.h. Recommendedoff-roadtowingspeed
is not to exceed 10 m.p.h. or less depending on terrain.
Whentowing,maintainextraspacebetween vehicles and avoid soft shoulders, curbs and sudden lane
changes. Ifyou have not pulled a trailer before, practice turning, stopping, and backing up in an area
awayfrom heavytraffic.
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.
TOWINGSAFETY
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 immedi-
atelyinformtheNationalHighwayTrafficSafetyAdministration (NHTSA) in addition to notifying Magnum Products
LLC. If NHTSA receives similar complaints, it may open an investigation; and if it finds that a safety defect exists in
agroup of vehicles, it may order a recall and remedy campaign. However,NHTSAcannotbecomeinvolvedin
individualproblem between you, your dealer,or Magnum ProductsLLC.
To contactNHTSA, youmay either call theAuto Safety Hotline toll-free at 1-888-327-4236or by fax at: (202)-366-
7882. Additionalcontactinformationcanbefound at: www.nhtsa.dot.gov.
UNIT SERIAL NUMBER LOCATIONS
Refer to the locations illustrated below to find the unit ID
tag,and trailer ID tagon your unit. Important information,
such as the unit serial number, model number and
VehicleIdentificationNumber(V.I.N.)for your trailer are
foundonthese tags. Record the information from these
tags, so it is available if the tags are lost or damaged.
Whenordering parts or requesting technical service
information, you may be asked to specify this informa-
tion.
MANUFACTURED BY/FABRIQUE PAR:
GVWR/PNBV:
DATE OF MFG:
COLD INFL. PRESS./PRESS.
DE GONF A FROID
GAWR/PNBE TIRE/PNEU RIM/JANTE KPA(PSI/LPC) SGL/DUAL
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:
MANUFACTUREDBY/FABRIQUEPAR:
GVWR/PNBV:
DATEOFMFG:
COLDINFL.PRESS./PRESS.
DEGONFAFROID
GAWR/PNBE TIRE/PNEU RIM/JANTE KPA(PSI/LPC) SGL/DUAL
THISVIEHICLECONFORSTOALLAPPLICABLE STANDARDS PRESCRIBED UNDER THE CANADIAN MOTOR VIEHICLE SAFETY REGULATIONS
INECCEFTONTHEDATEOF MANUFACTURE. /CEVEHICULEESTCONFORMEATOUTES LES NORMES QUI LUI SONT APPLICABLES EN
VERTUDUREGLEMENTSURLAVEHICULES DES AUTOMOBILES DU CANADA EN VIGUEUR A LA DATE SA FABRICATION.
THISVIEHICLECONFORMSTOALLAPPLICABLE U.S. FEDERAL MOTOR VEHICLE SAFETY STANDARDS (FMVSS) IN EFFECT ON THE DATE OF
MANUFACTURESHOWNABOVE.
V.I.N./N.I.V.: TYPE/TYPE DE VEHICULE:
SerialNumber
kg lbs
rpm hz amb. temp.
V
A
Model
RATING: CONT. STAND BY
3Phase 1Phase
KVA
LR114630-1
FORELECTRICAL
EQUIPMENTONLY.
POURMATERIAL
ELECTRIQUESEULEMENT.
MADEINUSAPRODUCTS LLC
215PowerDrive
Berlin,WI54923
1-800-926-9768
TM
Mfg.Code
V
A
KW
®
Serial Number
kg lbs
rpm hz amb. temp.
V
A
Model
RATING: CONT. STAND BY
3 Phase 1 Phase
KVA
LR 114630-1
FOR ELECTRICAL
EQUIPMENT ONLY.
POUR MATERIAL
ELECTRIQUE SEULEMENT.
MADE IN USA
PRODUCTS LLC
215 Power Drive
Berlin, WI 54923
1-800-926-9768
TM
Mfg. Code
V
A
KW
®
Unit ID Tag
V.I.N. Tag
Located on inside
of panel.

SAFETY SYMBOL SUMMARY
Thisequipmenthasbeensuppliedwithnumeroussafetyandoperatingdecals. Thesedecalsprovideimportant
operatinginstructions and warnofdangersand hazards. Replace anymissingorhard-to-read decals andusecare
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.
UV
Hot surface(s) nearby.
Fire/explosion hazard; Keep
open flames away from unit.
Read and understand the
supplied operator’s manual
before operating unit.
Ultraviolet radiation hazard;
Operate only with lens intact.
Use clean diesel fuel only.
Unit electrical ground.
Anchor/tie down point.
Lift here only.
Asphyxiation hazard; Operate
in well ventilated area.
Dangerous voltage may be
present.
Crush hazard; Keep body parts
clear of this area.
Burn/scald hazard;
pressurized steam.
Fan hazard; Keep body parts
clear of this area. Forklift here only.
Belt/entanglement hazard; Keep
body parts clear of this area.
Safety alert symbol; Used to
alert you to potential personal
injury hazards.
Stop engine before fueling.
7

8
SPECIFICATIONS
Readthismanual carefully before attempting to use this lighttower. The potential forpropertydamage, 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.
MAGNUMMODEL MLT 4250
Engine
Make/Brand ........................................................ Isuzu
Model.................................................................. 4LE1-NYGV-01
Type .................................................................... Diesel,liquid cooled, 4-stroke
Horsepower-primehp (kW) ............................... 31.5 (23.5)
Horsepower-standby hp (kW) ........................... 34.5(25.7)
OperatingSpeedrpm ......................................... 1800
Displacement in3(L) ........................................... 134.25(2.20)
Cylinders - qty .................................................... 4
Fuel Consumption - 100% prime gph (Lph) ....... 1.80(6.81)
BatteryType- Group Number ............................. 24
Battery Voltage (Quantity per Unit) ..................... 12V(1)
BatteryRating..................................................... 720CCA
Generator
Make/Brand ........................................................ MarathonElectric
Model.................................................................. 282NSL1505
Type, Insulation................................................... Brushless, H
Generator Set (Engine/Generator)
3Ø - Standby kW (kVA) ...................................... 20(25)
Amps - 3Ø Standby - 480 (208V) A..................... 30(69)
3Ø - Prime kW (kVA) .......................................... 18(23)
Amps - 3Ø Prime - 480 (208V) A ........................ 28(64)
1Ø - Standby - kW (kVA) .................................... 16.0(16.0)
Amps - 1Ø Standby - 240V A.............................. 67
1Ø - Prime - kW (kVA)........................................ 15.0 (15.0)
Amps - 1Ø Prime - 240V A................................. 63
FrequencyHz ..................................................... 60
PowerFactor ...................................................... 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
DryWeightlbs (kg)............................................. 2158 (979)
OperatingWeight lbs (kg) ................................... 2556(1159)
Capacities
Fuel Tank Volume 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

9
SPECIFICATIONS
Readthismanual carefully before attempting to use this lighttower. The potential forpropertydamage, 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.
Lighting
LightingType....................................................... Metal Halide
BallastType........................................................ Coil & Core
Lumens ............................................................... 440,000
Coverageacres (m2)........................................... 5 - 7 (20,234 - 28,328)
ACDistribution
Circuit Breaker Size............................................ 90
VoltageSelection ................................................ 3 Position Switch (lockable)
VoltageRegulation .............................................. +/-1%
VoltagesAvailable1Ø ......................................... 120, 139, 208, 220, 240, 277
VoltagesAvailable3Ø ......................................... 208,220, 440, 480
Trailer
NumberofAxles ................................................. 1
Capacity -Axle Rating lbs (kg) ........................... 3000(1361)
Tire Size in ......................................................... 15
Hitch -Standard .................................................. 2" Ball
MaximumTirePressurepsi ................................ 50

1
2
3
4
5
6
1. FUEL FILLER LOCATION (under door): UsecleanDIESELFUELONLY.
2. RADIATORACCESS PANEL: Removethis panelfor engine coolant service.
3. CONTROL PANEL LOCATION (under door): Engine/generatorcontrolsandallcircuitbreakers.
4. EMERGENCY STOP SWITCH: Foremergency shutdown;stopsengine and tripsmain circuit breaker.
5. EQUIPMENT OUTLETS: Circuitbreakerprotected outlets; 20, 30 and/or 50 ampratings.
6. GROUND STUDS (2): Forgroundinggeneratorandequipmentconnectedtotheequipmentoutlets.
EXTERIOR LOCATIONS
10

7
10
13
4
2
2
1
3
6
9
12
5
8
11
MAIN CONTROL PANEL COMPONENTS
1. MAIN CIRCUIT BREAKER (90A): Thisbreakerwill disconnect power to the connection lugs.
2. LUG DOOR SAFETY SWITCHES: Theseswitches willshutthegenerator down if thelugdooris opened when the
generatoris running.
3. GENERATOROUTPUT CONNECTION LUGS:Theseallow appropriateloadsto bewireddirectly tothegenerator.
4. GENERATORGROUND CONNECTION LUG:Thislug isforconnecting agood earthengroundper anylocal, state
orNational Electric Code (NEC) guidelines before startingthegenerator.
5. REMOTE START TERMINAL BLOCK:Allows connections forremotestartingofthegenerator.
6. CABLEACCESS:Allows for entry of load cables to the connection lugs with the lug box door closed.
7. PHASESELECTOR SWITCH: This switchwillchange thegeneratoroutput betweenthreephase andsinglephase
power. See the VOLTAGESELECTORSWITCHsectionformoreinformation.
8. VOLTAGEADJUSTMENT RHEOSTAT: Usedtofinetunegenerator output voltage.
9. CONTROL POWER SWITCH: Thisis the main power switch for the controller in MANUALorAUTOmode.
10. ENGINE CONTROL PANEL: Seepages12-13 for additional information.
11. BALLAST INDICATOR LIGHTS: Indicates power from the ballastto each light.
12. INDIVIDUAL CIRCUIT BREAKERS: One breaker is supplied for eachlight.
13. AUXILIARY OUTLET MAIN CIRCUIT BREAKER (100A): Thisbreakerdisconnectspowertotheauxiliaryequip-
ment outlets.
11

MAGNUM DIGITAL CONTROLLER (MDC)
TheMagnum Digital Controller (MDC) is an enhanced digital generator controller used to start, stop and monitor the
operationof the generator and the engine. Thecontroller constantly monitors vital generatorand engine functions
fora number of pre-programmed alarm and fault conditions. When afault condition occurs, the engine will shut
down automatically and the Liquid Crystal Display (LCD) window will display the fault that caused the shutdown; to
resumeoperation the fault condition must be resolved. The controller has the ability to provide thedisplay readout
in English and Spanish; other languages are available.Ascreen 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
removedorlost when the controller is powered down.
TheMDC panelconsistsof five sections, including: the “CONTROLON” / “CONTROLOFF”Toggle Switch andFine
VoltageAdjustmentScrew;the “OPERATION” keypad;the LCDwindow; the “DIAGNOSTICS” keypad; and the
“STATUS” Light Emitting Diodes (LED’s). The following is a brief summary of the operation of each section of the
controlpanel:
1. The “CONTROL ON” / “CONTROL OFF” Toggle Switch and Fine Voltage Adjustment Screw
• ControlOn/OffToggleSwitch
Thistoggle switch powers-up the control panel and the controller.
• FineVoltageAdjustment 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 “OPERATION” Keypad
• “ENGINESTART”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 START” button to
start the unit.
• “ENGINESTOP”Button
Press the red “ENGINE STOP” button to shut down the unit and start the “Stop Value” timer.
• “MANUALW”Button
Press this button to change from theAutomatic (Remote) starting mode to Manual starting mode.
• “AUTO XX
XX
X”Button
Press this button to change from Manual starting mode toAutomatic (remote) starting mode.
0kW
Ready
PF 0.00
RPM 0
0
MAN AUT
1
2
3
4
5
12

• “ALARMCANCEL”Button
When an alarm is activated, either visually or audibly, press this button to silence or cancel the alarm.
• “FAULTRESET” Button
Press this button to clear the fault from the LCD window after the fault has been corrected.
Press“FAULT RESET” and “ENTER” to clear the John Deere ECUAlarm List Codes.
3. The Liquid Crystal Display (LCD)
• Thiswindow 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.
• “PAGESELECT” Button
Pressing this button will select the next display screen.
• “ENTER”Button
Pressingthis button will place you inside the particular display to review the generators preprogrammed
setpointsor parameters.
5. The “STATUS” 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
Generatorinformation is shown onthe Liquid Crystal Display (LCD) window in a toggling manner with the Engine
informationafterthe first 60 seconds of operation, then every fiveseconds thereafter.The generator display screen
willshow frequency, line to neutralvoltage,line to line voltageand amperage.
Note: When loading the generator, it is important 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: Displaysoutput frequency.
•Generator Output Voltage: Line to Neutral display, single phase (1Ø).
•Generator Output Voltage: Line to Line display, 3 phase (3Ø).
•Amps: DisplaystheAC output amperage produced by thegenerator.
13

ENGINE MONITORING
Engineinformation is shown onthe Liquid Crystal Display (LCD) window in a toggling manner with the Generator
informationafterthe first 60 seconds of operation and then every5 seconds thereafter.The engine display screen
willshow oil pressure, engine coolant temperature,fuel level and battery voltage.
• Oil Press: Displaysengine oil pressure. The display registers oil pressure between 0-100 psi.
Normaloperatingpressure is between 35-80 psi.
• Eng Temp: Displays the temperature of the engine’s coolant. If the coolant temperature exceeds the
MaximumWaterTemperature 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
lowfuel warning and optional audio alarmwill be activated. If the fuellevel drops below
the programmed low fuel limit, usually at 5%, the engine will automatically shut down.
(Note:The MLG 25 doesnot display fuel level).
• Vbat: Displays the engine battery voltage.Anormal reading is 13-14V on 12 volt systems and
24-26on 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 “DIAG-
NOSTICS”keypad to display additional information asfollows:
• “Running” screen:
The operator may press the “S” or “T” buttons on the “DIAGNOSTICS” keypad to
display the “Alarm List” screen, “ECUAlarm List” screen, “Run Hours” screen, “ECU
Values”screen, Engine display screen and Generator display screen.
• “Password” screen:
Theoperator may press the “S” or “T” buttonson the “DIAGNOSTICS” keypadto move
the “>” cursor up or down a list of text.
• “History” screen:
Theoperator may press the “S” or “T” buttonson the “DIAGNOSTICS” keypadto 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
LCDwindow to view the generatoroperating parameters at the time of the alarm or
shutdown.
14

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 118 codes. When full, the controller
will automatically remove the oldest file. These codes will not be lost when the control
powertoggle switch is powered off.
FINE VOLTAGE ADJUSTMENT
Uponstart-upof thegenerator, the“Running” screen of the MagnumDigital
Controller(MDC) will display “SENSING” and willcountdown from 45 seconds
to “0” Zero. This is a safety feature of the controller to protect the generator
fromover or under voltage upon start-up.
“SENSING” is a 45 second time delay and count down process before the
MDCrecordsthegeneratornominal output voltage. This nominal generator
voltageis then compared to the current set point voltage ofthe voltage selec-
tor 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.Thismeans the controller warned (“Wrn”) or even shut down (“Sd”) theunit due to an output voltage
irregularity.
Theoutput voltage of the generator may be adjusted afterthe generator is running by use of the fine voltage adjust-
ment 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
madewithin the 45 seconddelay and countdown to “0” Zero period.
To adjust the output voltage,check the output voltageonthe Liquid CrystalDisplay (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
untilthe 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
WnVG1 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.
CONTROL
ON
CONTROL
OFF
VOLTAGE
A
DJUSTMENT
RHEOSTAT
15

MAGNUM DIGITAL CONTROLLER (MDC) INFORMATION DISPLAYS, FUNCTIONS AND
RESET
TheMagnumDigital Controller (MDC) constantly monitors vital generatorand 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. To reset the controller and resume operation, press the “FAULT RESET”
button.
MAGNUM DIGITAL CONTROLLER (MDC) – GENERATOR OPERATIONAL STATUS
TheMagnum Digital Controller (MDC) displays the operational status ofthe generator using the following codes:
MAGNUM DIGITAL CONTROLLER (MDC) - ALARM MANAGEMENT
TheMagnum Digital Controller (MDC) is capableof displaying the following alarms:
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.
16

MAGNUM DIGITAL CONTROLLER (MDC) - LIST OF POSSIBLE ALARMS/DESCRIPTIONS
Shutdown and warning fault conditions and the displayed message aredescribed in the following table:
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.
17

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 DIGITAL CONTROLLER (MDC) – HISTORY
TheMagnum Digital Controller (MDC) controller stores a record of each important event into the history file of the
controller. The history file seats 118 records. When the history file is full, the oldest records are removed.
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
18

ADJUSTING THE DISPLAY BACK LIGHTING
Thebacklighting on the Liquid Crystal Display (LCD) window may be adjusted brighter or darker by the operator
whenevertheMagnumDigitalController(MDC)ispoweredup.
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
TheMagnum Digital Controller (MDC) will display the message “WrnServiceTime” when the unit is due for mainte-
nance or service. The maintenance or service interval is set at 250 hours of engine running time. Once the unit has
beenserviced,the“ServiceTime”reminder needs to be reset to the 250 hour interval. Thefollowingprocedure
demonstrates how to reset the running hours to 250:
1. With the unit shut down, power up the controller with the “Control On/Off” Toggle 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.
19

TIGHTEN CONNECTION
LUGS WITH A HEX WRENCH
GENERATOR OUTPUT CONNECTION LUGS
Thegeneratorisequippedwithconnectionlugsbehindadoorbelowthecontrollerface. Thelugsprovideconnection
points for attachment of external loads to the generator. Alarge decal on the inside of the connection lug door
detailstheproperconnectionsforselectedvoltages.
Connectionsto 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
tripthemaincircuitbreakeranddisable the voltage regulator when
the lug door is opened. Use a hex-wrench to tighten the cable
connections.
A ground connection is located next to the connection lugs. The
unit MUST HAVE thisground lug connected to a good earthen
groundfor proper operating safety. The ground connectionshould
be in compliance with the National Electric Code (NEC) as well as
any state or local guidelines or codes.
20
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.
IMPROPEROR INCORRECT CONNECTIONS TO A BUILDINGS ELECTRICALSYSTEM CAN CAUSE
POTENTIALLYLETHAL VOLTAGE TO BACKFEED ONTO UTILITY LINES. THIS MAY RESULT IN
INJURYOR ELECTROCUTION TO UTILITY WORKERS NEARBY. MAKE SURE THE GENERATORIS
SUPPLYING POWER TOAN ISOLATED OBJECT OR BUILDING THAT IS NOT CONNECTED TOANY
UTILITY LINES.
DANGER
Never attempt to disable or modify the lug door
safety switches. Equipment damage, personal
injury or death may result.
WARNING