Generac Power Systems Magnum MTT25 Bedienungsanleitung

COMBINATION LIGHT TOWER

GENERATOR & WATER TRAILER

01203

MTT25 • MTT25CAN

OPERATING MANUAL

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INTRODUCTION

This manual provides information and procedures to safely operate and maintain the Magnum Power Products LLC

unit. For your own safety and protection from physical injury, carefully read, understand, and observe the safety

instructions described in this manual. Keep a copy of this manual with the unit at all times. The information

contained in this manual was based on machines in production at the time of publication. Magnum Power Products

LLC reserves the right to change any portion of this information without notice.

Read all of the manuals included with the unit. Each manual details specific information regarding items such as

setup, use and service requirements. An engine operator’s manual provides detailed operation and maintenance

procedures for the engine. Additional copies of the engine operator’s manual are available from the engine

manufacturer.

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

Magnum Power Products LLC recommends that a trained and licensed professional perform all electrical wiring

and testing functions. Installation should be in compliance with the National Electrical Code (NEC), state and

local regulations and Occupational Safety and Health Association (OSHA) guidelines.

Engine Make:__________________________________________

Engine Serial Number:___________________________________

Engine Model Number: __________________________________

Generator Make: _______________________________________

Generator Model Number: ________________________________

Generator Serial Number: ________________________________

Unit Model Number:_____________________________________

Unit Serial Number: _____________________________________

WARNING

CALIFORNIA PROPOSITION 65 WARNING: Diesel engine exhaust and some of its

constituents are known to the state of California to cause cancer, birth defects and

other reproductive harm.

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TABLE OF CONTENTS

Page

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

SAFETY NOTES ................................................................................................................................ 5

OPERATING SAFETY ....................................................................................................................... 5

ENGINE SAFETY............................................................................................................................... 6

SERVICE SAFETY............................................................................................................................. 7

TOWING SAFETY.............................................................................................................................. 7

REPORTING TRAILER SAFETY DEFECTS ..................................................................................... 8

SAFETY SYMBOL SUMMARY .......................................................................................................... 9

SPECIFICATIONS (1 OF 2) ............................................................................................................. 10

SPECIFICATIONS (2 OF 2) ............................................................................................................. 11

UNIT DIMENSIONS ........................................................................................................................ 12

UNIT SERIAL NUMBER LOCATIONS ............................................................................................ 13

COMPONENT LOCATIONS ............................................................................................................ 14

LIGHT TOWER SET UP................................................................................................................... 15

RAISING THE MAST........................................................................................................................ 16

RAISING THE MAST WITH ELECTRIC WINCH OPTION............................................................... 17

MAIN CONTROL PANEL ................................................................................................................. 18

MAGNUM DIGITAL CONTROLLER (MDC) ..................................................................................... 19

DIGITAL CONTROLLER FEATURES AND FUNCTIONS ............................................................... 19

GENERATOR MONITORING .......................................................................................................... 20

ENGINE MONITORING ................................................................................................................... 20

MDC INFORMATION DISPLAYS, FUNCTIONS, AND RESET ....................................................... 22

MAGNUM DIGITAL CONTROLLER (MDC) – OPERATIONAL STATUS ........................................ 22

MAGNUM DIGITAL CONTROLLER (MDC) - ALARM MANAGEMENT........................................... 22

MAGNUM DIGITAL CONTROLLER (MDC) - LIST OF ALARMS .................................................... 23

MAGNUM DIGITAL CONTROLLER (MDC) – HISTORY ................................................................. 24

ADJUSTING THE DISPLAY BACKLIGHTING ................................................................................. 24

GENERATOR OUTPUT CONNECTION LUGS ............................................................................... 24

VOLTAGE SELECTOR SWITCH ..................................................................................................... 25

PRESTART CHECKLIST ................................................................................................................. 26

EMERGENCY STOP SWITCH ........................................................................................................ 27

MANUAL STARTING OF THE UNIT................................................................................................ 27

AUTO (REMOTE) STARTING OF THE UNIT .................................................................................. 29

AUTOMATIC SHUTDOWN ..............................................................................................................29

LIGHT OPERATION......................................................................................................................... 29

VOLTAGE REGULATION ................................................................................................................ 30

DERATING FOR ALTITUDE ............................................................................................................ 30

WET STACKING .............................................................................................................................. 30

RECEPTACLE PANEL..................................................................................................................... 31

MAIN CIRCUIT BREAKER............................................................................................................... 31

REMOTE START TERMINAL BLOCK ............................................................................................. 32

TRANSFER SWITCH ....................................................................................................................... 32

AUTO EXERCISE TIMER ................................................................................................................ 33

FINE VOLTAGE ADJUSTMENT ...................................................................................................... 33

SHUTTING DOWN THE UNIT ......................................................................................................... 34

USING THE WATER SUPPLY......................................................................................................... 34

LOWERING THE MAST - MANUAL................................................................................................. 35

LOWERING THE MAST - ELECTRIC WINCH OPTION.................................................................. 36

REMOVING THE LIGHTS FOR TRANSPORTATION ..................................................................... 37

TOWING THE UNIT ......................................................................................................................... 37

LIFTING THE UNIT .......................................................................................................................... 38

GENERAL MAINTENANCE .............................................................................................................38

BASIC MAINTENANCE SCHEDULE - ISUZU ENGINE .................................................................. 40

RESETTING THE TIME TO SERVICE REMINDER ........................................................................ 40

WINCH USE, OPERATION & MAINTENANCE - MANUAL ............................................................. 41

WINCH USE, OPERATION & MAINTENANCE - ELECTRIC .......................................................... 42

JACK MAINTENANCE ..................................................................................................................... 42

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TRAILER WHEEL BEARINGS ......................................................................................................... 43

LOWER RADIATOR HOSE HEATER OPTION - USE AND MAINTENANCE................................. 43

TROUBLESHOOTING AUTOMATIC SHUTDOWN CONDITIONS ................................................. 44

TROUBLESHOOTING THE LIGHTS ............................................................................................... 45

MAST LIGHT CONNECTIONS ........................................................................................................ 46

AC WIRING DIAGRAM .................................................................................................................... 47

AC WIRING DIAGRAM - RECEPTACLE PANEL ............................................................................ 48

AC WIRING DIAGRAM - RECEPTACLE PANEL OPTIONS (1 OF 2)............................................. 49

AC WIRING DIAGRAM - RECEPTACLE PANEL OPTIONS (2 OF 2)............................................. 50

DC WIRING DIAGRAM .................................................................................................................... 51

DC WIRING DIAGRAM - ELECTRIC WINCH .................................................................................. 52

DC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT................................................................ 53

TRAILER LIGHTS WIRING DIAGRAM ............................................................................................ 54

SERVICE LOG ................................................................................................................................. 55

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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, WARN-

INGS, CAUTIONS, NOTICES and NOTES.

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

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Indicates a hazardous situation which, if not avoided, could result in property or equipment

damage.

Note: Notes contain additional information important to a procedure and will be found within the regular text body

of this manual.

OPERATING SAFETY

Before using the unit, be sure to read and understand all of the instructions. This equipment was

designed for specific applications; DO NOT modify or use this equipment for any application other than

which it was designed for. Equipment operated improperly or by untrained personnel can be dangerous.

Read the operating instructions and familiarize yourself with the location and proper use of all instruments

and controls. Inexperienced operators should receive instruction from someone familiar with the equipment

before being allowed to operate or set up the unit. The following points should be practiced at all times:

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

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

•NEVER start a unit in need of repair.

•ALWAYS lower the mast when not in use, or if high winds or electrical storms are expected in the area.

• Make certain the unit is securely fastened to a good earthen ground. Follow the National Electrical

Code (NEC), state and local regulations.

•NEVER operate the unit on a combustible surface.

• The mast extends up to 31.5 ft (9.6m). ALWAYS make sure the area above the unit is open and clear

of overhead wires and obstructions.

• Keep area around the unit clear of people while raising and lowering the mast.

• Keep all body parts, clothing, and other loose items clear of winch and cable during operation and

while in tension.

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

handling.

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

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• If for any reason any part of the mast hangs up or winch cable develops slack while raising or lowering

the mast, STOP immediately and contact an authorized service representative.

•NEVER remove safety pin or pull mast locking pin while the mast is up.

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

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

or damaged.

• Only use mild soap and water to clean the lens covers. Other chemicals may have an adverse effect

on the glass.

•NEVER operate a unit while tired, distracted, or under the influence of drugs or alcohol.

•NEVER use water in the supply tank for human consumption.

•ALWAYS keep the water tank cover in place. Stay out of tank.

•DO NOT drive over the hoses while they are pressurized or while the pump is running.

•NEVER leave the unit unattended while the pump is running.

ENGINE SAFETY

Internal combustion engines present special hazards during operation and fueling. Failure to follow the

safety guidelines described below could result in severe injury or death. Read and follow all safety warnings

described in the engine operator's manual. A copy of this manual was supplied with the unit when it was

shipped from the factory.

•DO NOT run engine indoors or in an area with poor ventilation unless exhaust hoses are used. Diesel

engine exhaust contains carbon monoxide, a deadly, odorless and colorless gas which, if inhaled,

can cause nausea, fainting or death. Make sure engine exhaust cannot seep into closed rooms or

ventilation equipment.

•DO NOT operate the unit on a combustible surface.

•DO NOT fill fuel tank near an open flame, while smoking, or while engine is running. DO NOT fill tank

in an enclosed area with poor ventilation.

•DO NOT operate with the fuel tank cap loose or missing.

•DO NOT touch or lean against hot exhaust pipes or engine cylinders.

•DO NOT clean air filter with gasoline or other types of low flash point solvents.

•DO NOT remove engine coolant cap while engine is hot.

•DO NOT operate the unit without a functional exhaust system. Prolonged exposure to sound levels

in excess of 85 dB(A) can cause permanent hearing loss. Wear hearing protection when working

around a running engine.

• Keep area around exhaust pipes and air ducts free of debris to reduce the chance of an accidental fire.

• Batteries contain sulfuric acid which can cause severe injury or death. Sulfuric acid can cause eye

damage, burn flesh or eat holes in clothing. Protective eye wear and clothing are necessary when

working on or around the battery. Always disconnect the negative (-) battery cable from the

corresponding terminal before performing any service on the engine or other components.

• Shut the engine down if any of the following conditions exist during operation:

1. Noticeable change in engine speed.

2. Loss of electrical output and/or pumping output.

3. Equipment connected to the generator overheats.

4. Sparking occurs.

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

6. Protective covers are loose or missing.

7. If the ambient air temperature is above 120°F (49°C).

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SERVICE SAFETY

This unit uses high voltage circuits capable of causing serious injury or death. Only a qualified and

licensed electrician should troubleshoot or repair electrical problems occurring in this equipment.

• Before servicing, make sure the Control Power switch and circuit breakers are in the OFF (O) position,

and the negative terminal on the battery is disconnected. NEVER perform even routine service (oil/

filter changes, cleaning, etc.) unless all electrical components are shut down.

•NEVER allow water to accumulate around the base of the unit. If water is present, DO NOT service.

•ALWAYS use extreme caution when servicing the unit in damp conditions. NEVER service the unit if

your skin or clothing is wet. DO NOT allow water to collect/accumulate around the base of the unit. If

water is present, DO NOT service. 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 high pressure hoses or power washers.

• Open the main circuit breaker before disconnecting battery cables.

• Keep all body parts, clothing, and other loose items away from moving parts on the unit.

• Make sure slings, chains, hooks, ramps, jacks, and other types of lifting devices are attached securely

and have enough weight-bearing capacity to lift or hold the unit safely. Always remain aware of the

position of other people around when lifting the unit.

•NEVER start the unit under load. The circuit breakers must be in the OFF (O) position when starting

the unit in Manual mode. The circuit breakers can be in the ON (I) position only when started in the

Auto mode. A transfer switch must be used in the Auto mode to deflect the load upon startup.

•ALWAYS disconnect the negative (-) battery cable from the corresponding terminal before performing

any service on the engine, generator or any other components. Remove the negative (-) battery cable

from the corresponding terminal if the unit is to be stored or transported.

• Replace all guards and safety devices immediately after servicing.

• Wear heavy leather gloves when handling winch cables. Never let cables slip through bare hands.

TOWING SAFETY

Towing a trailer requires care. Both the trailer and vehicle must be in good condition and securely fastened

to each other to reduce the possibility of an accident. Some states require that large trailers be registered

and licensed. Contact your local Department of Transportation office to check on license requirements for

your particular unit.

• Check that the hitch and coupling on the towing vehicle are rated equal to, or greater than, the trailer's

Gross Vehicle Weight Rating (GVWR).

• Check tires on trailer for tread wear, inflation, and condition.

•NEVER tow trailer using defective parts. Inspect the hitch and coupling for wear or damage.

• Make sure the trailer hitch and the coupling are compatible. Make sure the coupling is securely fastened

to the vehicle.

• Connect safety chains in a crossing pattern under the tongue and ATTACH THE BREAKAWAY

CABLE TO THE REAR BUMPER OF THE TOWING VEHICLE. Do not attach the cable to the trailer

hitch.

• Make sure directional and brake lights on the trailer are connected and working properly.

• Check that all lug nuts holding wheels on are tight and none are missing.

• Maximum recommended speed for highway towing is 45 mph (72 km/h). Recommended off-road

towing speed is not to exceed 10 mph (16 km/h) or less, depending on terrain.

• 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.

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• Towing the unit with water in the tank will adversely affect handling of towing vehicle, specifically

maneuvering corners, accelerating, and braking. Ensure operator has experience with towing unit.

• Maximum recommended towing speeds for the unit are as follows:

With the tank empty, improved road: .................................. 55 mph (89 km/h)

With the tank full, improved road: ....................................... 45 mph (72 km/h)

With the tank 1/2 full, improved road: ................................. 45 mph (72 km/h)

Any towing on unimproved roads:....................................... 20 mph (32 km/h) or less

• Reduce speed when the tank is filled with water. The tank is not baffled. There will be a noticeable

water surge in the tank under heavy braking.

• Before towing the trailer, check that the weight of the trailer is equal across all tires. Adjust the angle

of the trailer tongue to keep the trailer as level as possible. A large angle between the trailer and tow

vehicle will cause more weight to be carried by one axle, which could cause premature wear on the

tires and axles and cause potentially unsafe operating conditions.

• The trailer is equipped with hydraulic surge brakes or electric surge brakes. Check the operation of

the brakes by braking the vehicle at a slow speed before entering traffic. Both the trailer and the vehicle

should brake smoothly. If the trailer seems to be pushing, check the level in the surge brake fluid

reservoir.

• 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 Traffic Safety Administration (NHTSA) in addition to notifying Magnum Power Products

LLC.

If NHTSA receives similar complaints, it may open an investigation; and if it finds that a safety defect exists in a group

of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in an individual

problem between you, your dealer, or Magnum Power Products LLC.

To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-888-327-4236 (TTY:1-800-424-9153),

go to http://www.safercar.gov; or write to:

Administrator

NHTSA

1200 New Jersey Avenue S.E.

Washington, DC 20590

You can also obtain other information about motor vehicle safety from http://www.safercar.gov.

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SAFETY SYMBOL SUMMARY

This equipment has been supplied with numerous safety and operating decals. These decals provide important

operating instructions and warn of dangers and hazards. Replace any missing or hard-to-read decals and use care

when washing or cleaning the unit. Decal placement and part numbers can be found in the parts manual. Below is

a summary of the intended meanings for the symbols used on the decals.

Hot surface(s) nearby. Dangerous voltage may be

present.

Anchor/tie down point.

Belt/entanglement hazard; keep

body parts clear of this area.

Use clean diesel fuel only.

Crush hazard; keep body parts

clear of this area.

UV Ultraviolet radiation hazard;

operate only with lens intact.

Burn/scald hazard;

pressurized steam.

Fire/explosion hazard; keep

open flames away from unit. Unit electrical ground.

Asphyxiation hazard; operate

in well ventilated area.

Safety alert symbol; used to

alert you to potential personal

injury hazards.

Read and understand the

supplied operator’s manual

before operating unit.

Stop engine before fueling.

Fan hazard; keep body parts

clear of this area.

Isolate generator to prevent

electrocution hazard.

Never change switch position

while engine is running.

Stop engine before making

connections.

Remove negative battery

cable before performing

any service on unit.

Engine running.

Do not step on this surface.

Do not stand on this surface.

Stay out of tank.

Stand clear while mast

is being operated.

Do not drink the water. Do not lift.

00199

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