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Magnum MLG 25 Operations & Parts Manual

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DIESEL GENERATOR
MLG 25
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OPERATION/PARTS MANUAL

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Summary of Contents for Magnum MLG 25

  • Page 1 DIESEL GENERATOR MLG 25 - l l OPERATION/PARTS MANUAL...
  • Page 2 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 IS BASED ON MACHINES IN PRODUCTION AT THE TIME OF PUBLICATION. MAGNUM PROD- UCTS LLC RESERVES THE RIGHT TO CHANGE ANY PORTION OF THIS INFORMATION WITH- OUT NOTICE.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS PAGE 3 SAFETY NOTES PAGE 4 UNIT SERIAL PLATE LOCATION PAGE 4 SAFETY NOTES PAGES 5 - 6 SPECIFICATIONS PAGE 7 EXTERIOR LOCATIONS PAGE 8 MAIN CONTROL PANEL PAGE 9 ENGINE CONTROLLER FEATURES PAGES 10 - 11 GENERATOR AND ENGINE MONITORING PAGE 12 GENERATOR OUTPUT CONNECTION LUGS...

  • Page 4: Safety Notes

    Only a qualified electrician may service or make connections to the generator. Lethal voltage is present at the connection lugs when the generator is running! UNIT SERIAL PLATE LOCATION Magnum Products LLC Berlin, WI 54923 USA (800) 926-9768 MADE IN USA...
  • Page 5 OPERATING SAFETY Before using the generator be sure you read and understand all instructions! 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 generator.
  • Page 6 National Highway Traffic Safety Administration (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 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 Products LLC.

  • Page 7: Specifications

    SPECIFICATIONS Engine manufacturer ISUZU Engine model 4LE1-PV 05 Engine type Diesel, 4-cyl, liquid cooled 4-stroke Engine horsepower (standby) 34.5 hp (25.7 Kw) @1800 RPM Engine horsepower (primed) 31.5 hp (23.5 Kw) @1800 RPM Fuel tank capacity 56 gal. (215.8 L) Fuel consumption 2.1 gph (7.90 Lph) Generator manufacturer...

  • Page 8: Exterior Locations

    EXTERIOR LOCATIONS - l l 1. FUEL FILLER LOCATION (under door): Use clean DIESEL FUEL ONLY. 2. RADIATOR ACCESS PANEL: Remove this panel for engine coolant service. 3. CONTROL PANEL LOCATION (under door): Engine/generator controls and all circuit breakers. 4. EMERGENCY STOP SWITCH: For emergency shutdown; stops engine and trips main circuit breaker. 5.

  • Page 9: Main Control Panel

    MAIN CONTROL PANEL 1. MAIN CIRCUIT BREAKER (90A): This breaker will disconnect power to the connection lugs. 2. ENGINE CONTROLLER PANEL: See pages 10 - 11 for additional information. 3. AUXILIARY OUTLET MAIN CIRCUIT BREAKER (100A): This breaker disconnects power to the auxiliary equipment outlets.

  • Page 10: Engine Controller Features

    ENGINE CONTROLLER FEATURES CONTROL CONTROL OPERATION MAN AUT ENGINE ENGINE MANUAL AUTO START START Ready 0.00 CONTROL CONTROL ALARM FAULT ENGINE ENGINE CANCEL RESET STOP STOP DIAGNOSTICS STATUS PAGE ALARM/FAULT WARNING SELECT READY/MANUAL READY/AUTO ENTER RUNNING SUPPLYING LOAD 1. LCD DISPLAY This display shows the controller status in, MANUAL and AUTO (remote start) modes.
  • Page 11 6. DIAGNOSTICS DOWN Switch between: POWER SCREEN DISPLAY (DISPLAYS FROM MANUAL TO AUTO MODE) ALARM SCREEN DISPLAY HOUR SCREEN DISPLAY POWER DETAIL SCREEN DISPLAY Note: Automatically returns to flipping between the ENGINE / GENERATOR DISPLAY SCREENS after 60 seconds. PAGE SELECT Provides access to programming and resets. ENTER Allows access to the next level.
  • Page 12 GENERATOR MONITORING Generator information is shown on the LCD display in a repeating manner while the unit is running in MANUAL or AUTO mode. Generator information will show the voltage, amperage and frequency of each phase. Additional information can be viewed when the unit is MANUAL or AUTO modes. Pressing “PAGE SE- LECT”...

  • Page 13: Generator Output Connection Lugs

    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 electri- cian perform any wiring and related connections to the generator.

  • Page 14: Voltage Selector Switch

    VOLTAGE SELECTOR SWITCH The voltage selector switch is located on a panel attached to the generator behind the door located next to the fuel tank filler. The selector switch is a three position switch that mechanically changes the connec- tions between the generator output leads and the connection lugs on the main control panel. Voltage ranges are selected by rotating the handle on the switch to the desired voltage.

  • Page 15: Auxiliary Outlets

    AUXILIARY OUTLETS AUXILIARY OUTLET GROUNDING STUD 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 en- gine is running and the main circuit breaker and the auxiliary outlet main circuit breaker are switched on “I”.

  • Page 16: Main Circuit Breaker

    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”...
  • Page 17 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 manufac- turer 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.
  • Page 18 GENERATOR START UP Before starting the generator, carefully read the pre-start check list. Make sure that all of the items are checked before trying to start the generator. This check list applies for both manual and remote starting of the generator. PRE-START CHECK LIST 1.
  • Page 19 5. The Prestart screen will display (if equipped). OPERATION STATUS MAN AUT Prestart Prestart ALARM/FAULT WARNING 0.00 0.00 READY/MANUAL READY/AUTO Prestart Prestart RUNNING SUPPLYING LOAD 6. The Starting screen will display. The engine will crank and start running. OPERATION STATUS MAN AUT ALARM/FAULT WARNING...

  • Page 20: Shutting Down

    4. Move the control power switch to the CONTROL OFF/“O” position. EZ-1 CONTROLLER INFORMATION DISPLAYS AND FUNCTION The MAGNUM EZ-1 controller 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 automati- cally and the LCD display will show the fault that has caused the shut down.

  • Page 21: Controller Alarm List With Descriptions

    CONTROLLER ALARM LIST WITH DESCRIPTION Shutdown Alarm Display Description Possible Cause or Alarm Wrn Oil press Alarm Warning level of oil pressure reached Low oil, faulty sender, low engine oil pressure Sd Oil press Shut Down Shutdown Level of oil pressure reached Low oil, faulty sender, failed engine Fls Oil Pressure Alarm...
  • Page 22 CONTROLLER ALARM LIST WITH DESCRIPTION (CONTINUED) Shutdown Alarm Display Description Possible Cause or Alarm Sd StartFail Shut Down Engine failed to start after 3 attempts Fuel, air, engine, battery issue Com bus wiring issue, Engine ECU issue, J1939 Communication failure to the Wrn ECU Comm Alarm Battery disconnect switch off, blown fuse on...

  • Page 23: Towing The Trailer

    TROUBLESHOOTING AUTOMATIC SHUTDOWN CONDITIONS, CONTINUED OVERCRANK SHUTDOWN 1. Check the fuel level in tank. 2. Check for proper operation of the fuel pump. 3. If the engine will not start, consult the engine OPERATION AND MAINTENANCE MANUAL for additional information on troubleshooting starting problems. OVERSPEED OR UNDERSPEED SHUTDOWN 1.

  • Page 24: Engine And Generator Maintenance

    ENGINE AND GENERATOR 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.

  • Page 25: Daily Maintenance Checks

    DAILY MAINTENANCE CHECKS Check the engine oil level daily before starting engine. DO NOT start the generator if the oil level is below the ADD mark on the dipstick. The normal operating level for the engine oil is anywhere in the crosshatch pattern between the FULL and ADD markings.

  • Page 26: Frame Assembly

    FRAME ASSEMBLY 31 32...
  • Page 27 FRAME ASSEMBLY ITEM NO. PART NO. DESCRIPTION 15142 Fitting, .250NPT x .312 hose barb 12259 Fuel pick-up tube, 24.00 in. 12080 Cap, fuel tank vented - 3.5 in. green 16271 Fitting, .250NPT x .188 hose barb 12361B Weldment, fuel tank strap (small) 16270 Fitting, .375MNPT x .250FNPT 12162...

  • Page 28: Enclosure Assembly

    ENCLOSURE ASSEMBLY...
  • Page 29 ENCLOSURE ASSEMBLY ITEM NO. PART NO. DESCRIPTION 25333W Panel, back access 12195 Gasket, radiator access plate 11381 Fender, plastic 11507W Panel, right side sheetmetal 16591W Panel, door 16598 Hinge, door 10284W Panel, roof w/access hole 10287W Panel, rear 4000 isuzu 10220 Light, rear tail/turn mlt no grommet 10221...

  • Page 30: Auxiliary Outlet Panel Assembly

    AUXILIARY OUTLET PANEL ASSEMBLY...
  • Page 31 AUXILIARY OUTLET PANEL ASSEMBLY ITEM NO. PART NO. DESCRIPTION 65535 Clamp, 90° 3/4" 2 screw 12248B Weldment, outlet cover 10081 Hinge, continuous - 11.00 in. 11484B Cover, breaker 14130 Receptacle, 120V/20A GFCI 65530 Block, terminal - 2 pole lug type, 7 pos./pole 14137 Receptacle, 240V/30A twist lock 18089...

  • Page 32: Auxiliary Outlet Panel Options

    AUXILIARY OUTLET PANEL OPTIONS PART NUMBER 12399 PART NUMBER 12402 Receptacle Panel (2x5-20R, 3xL6-30R, 1x50A) Receptacle Panel (2x5-20R, 3xL6-20R, 1x50A) PART NUMBER 12400 PART NUMBER 12401 Receptacle Panel (2x5-20R, 3xL14-30R, 1x50A) Receptacle Panel (2x5-20R, 4xL14-30R)
  • Page 33 AUXILIARY OUTLET PANEL OPTIONS ITEM NO. PART NO. DESCRIPTION 14130 Receptacle, 120V/20A GFCI 14137 Receptacle, 240V/30A twist lock 18089 Receptacle, 120/240V 50A twist lock 65488 Receptacle, 240V/30A twist lock 14156 Breaker, 20A, 120V, 1 pole push button 65387 Breaker, 30A, 250V, 2 pole aux contact 65492 Breaker, 50A, 250V, 2 pole aux contact...

  • Page 34: Engine Cooling Assembly

    ENGINE COOLING ASSEMBLY...
  • Page 35 ENGINE COOLING ASSEMBLY ITEM NO. PART NO. DESCRIPTION 60034 Screw, .375-16X.750 hx ser flg ZP 60206 Washer, split lock .375 ZP 60386 Washer, flat .375 ZP 22238 Radiator, engine 11626B Weldment, fan shroud 15422 Clamp, hose SAE 20 11760B Panel, fan guard (RHT) 60115 Screw, M6X1.0X12 hx ser flg ZP 11769B...

  • Page 36: Engine Assembly

    ENGINE ASSEMBLY...
  • Page 37 ENGINE ASSEMBLY ITEM NO. PART NO. DESCRIPTION 21505 Assembly, air filter 60009 Screw, M8X1.25X25 hx ser flg ZP 12087B Bracket, air filter 60018 Screw, M10X1.25X20 hx ser flg 60316 Clamp, hose - SAE 32 60342 Nut, M8X1.25 hx GR8.8 SS 22320 Hose, air filter 19552...
  • Page 38 CONTROL PANEL ASSEMBLY FOR UNITS BUILT PRIOR TO MAY 2006...
  • Page 39 Lug, terminal single #6-250 MCM 12065 Channel, glastic 12066 Angle, glastic 11695W Panel, control 11811W Bracket, glastic plate - MLG 25 60020 Nut, M8 hx ser flg lock ZP 60062 Screw, 10-32X.750 pan hd phil ZP 60044 Screw, M5X0.8X12 pan hd phil ZP 60738...

  • Page 40: Control Panel Assembly, New Style

    CONTROL PANEL ASSEMBLY, NEW STYLE FOR UNITS BUILT AFTER MAY 2006...
  • Page 41 Lug, terminal single #6-350 MCM 12065 Channel, glastic 12066 Angle, glastic 12629W Panel, control 11811W Bracket, glastic plate - MLG 25 60020 Nut, M8 hx ser flg lock 60062 Screw, 10-32X.750 pan hd phil 60044 Screw, M5X0.8X12 pan hd phil 60738...
  • Page 42 CONTROL BOX ASSEMBLY FOR UNITS BUILT PRIOR TO MAY 2006...
  • Page 43 CONTROL BOX ASSEMBLY - FOR UNITS BUILT PRIOR TO MAY 2006 ITEM NO. PART NO. DESCRIPTION 11701B Panel, top control box - MLG25 18556 Regulator, voltage - SE 350 60045 Screw, M4X35 pan head phil ZP 60114 Screw, M8X1.25X20 hx ser flg ZP 60020 Nut, M8 hx ser flg lock ZP 60084...

  • Page 44: Control Box Assembly, New Style

    CONTROL BOX ASSEMBLY, NEW STYLE FOR UNITS BUILT AFTER MAY 2006...
  • Page 45 CONTROL BOX ASSEMBLY, NEW STYLE - FOR UNITS BUILT AFTER MAY 2006 ITEM NO. PART NO. DESCRIPTION 12694W Panel, top control box - MLG25 65619 Breaker, 90A, 3 pole 65429 Breaker, 100A, 250V, 2 pole 18556 Regulator, voltage - SE 350 60355 Screw, M4X35 pan head phil 65442...

  • Page 46: Lug Door Assembly

    LUG DOOR ASSEMBLY ITEM NO. PART NO. DESCRIPTION 18598 Hinge, controller panel - 18.75 60156 Screw, M5X0.8X16 pan hd phil ZP 60038 Nut, M5 hx nylock DIN985 ZP 20762 Lock, door - 1/4 turn cam 11710W Panel, lug door 12631W Panel, lug door (for units built after May ‘06) 15215 Bumper, rubber...

  • Page 47: Generator Assembly

    GENERATOR ASSEMBLY ITEM NO. PART NO. DESCRIPTION 60177 Screw, M10X1.25X30 hx hd 60206 Washer, split lock .375 ZP 11000 Plate, drive - SAE 7.5 11515B Spacer, 2.00 dia x 1.00 11524 Compression mount, engine 22899 Generator, 282NSL1505 11597B Bracket, gen mount...
  • Page 48 DC WIRING SCHEMATIC, FOR UNITS BUILT PRIOR TO MAY 2006...
  • Page 49 DC WIRING SCHEMATIC, NEW STYLE - FOR UNITS BUILT AFTER MAY 2006 BRN/WHT BRN/WHT RED F+ RED F+ BLK F- BLK F- 50HZ 50HZ 60HZ 60HZ...
  • Page 50 AC WIRING SCHEMATIC, FOR UNITS BUILT PRIOR TO MAY 2006...
  • Page 51 AC WIRING SCHEMATIC, NEW STYLE - FOR UNITS BUILT AFTER MAY 2006...
  • Page 52 CALIFORNIA PROPOSITION 65 WARNING DIESEL ENGINE EXHAUST AND SOME OF ITS CONSTITUENTS ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS AND OTHER REPRODUCTIVE HARM. REV: D PART NO: 12346 7.17.06...

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