Magnum MLT 4250 Operating & Parts Manual Download Page 71 | Manualshive

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90215, ORG 8.07.08

MDC CONTROLLER

2 PIN PLUG (RPM)

RPM IN

RPM GND

3 PIN

ANALOG INPUTS

OIL

IN

FUEL

IN

WA

T

E

R

I

N

AI1

AI2

AI3

NEUTRAL

COM

4

L1

L2

L3

CT

NEUTRAL

L3

L2

L1

REMOTE ST

AR

T

LOW COOLANT

OPTION

OPEN

OPEN

OPEN

BI1

BI2

BI3

B14

BI5

BI6

D

B

C

"OPTION"

PLUG LOCA

TION

BOTT

OM

BOTT

OM

PLUG LOCA

TION

LARGE 4 PIN GENERA

T

O

R VOL

T

AGE

PLUG LOCA

TION

TO

P

SMALL

4 PIN GENERA

T

O

R CURRENT

PLUG LOCA

TION

TO

P

7 PIN PLUG (BINAR

Y

INPUTS)

PLUG LOCA

TION

TO

P

OR

AL

TERNA

T

O

R

CUT

BACK SHEILD

AND T

APE

SHIELD

BLK

3NO

4NO

4NO

3NO

1NC

2NC

WHT

WHT

WHT

WHT

REMOTE ST

AR

T

BLU

L1

L2

AUX

BREAKER

CONTROL

POWER

C+

GLOW

RELA

Y

B+

BLK

YEL

C+

ST

AR

TER

RELA

Y

B+

BLK

YEL

60HZ

50HZ

WHT

RED F+

F-

F+

4

6

7

BRN/WHT

BLK

BLK F-

BRN

SE350

VOL

T

AGE REGULA

T

O

R

3

LUG DOOR

SW

VR

BLK

GN/YL

YEL

YEL

YEL

WHT

GR

Y

WT/BU

WT/VI

ORG

BRN

ORG

BRN

GR

Y

ORG

BLU

RED

ORG

WHT

RED

BLK

RED

RED

WHT

YEL

BLK

RED

GRN

YL/GN

BLK

BLK

BLK

BLK

WHT

BLK

BRN

GRN

RED

BLU

YEL

ORG

VIO

VIO

VIO

YEL

ORG

WHT

RED

RED

BLU

RED

BLK

WT/VI

YEL

WT/BU

GRY

BLK

VIO

BLK

BLK

RED

WHT

ORG

YL/GN

VIO

GRY

BLU

YEL

BRN

BR/WT

WHT

BLK

GRN

BLK

WHT

BRN

RED

BLK

RED

YEL

RED

GRY

LUG DOOR

SW

SHUNT

TRIP

YEL

ORG

WHT

WHT

FUSE

15 AMP

RED

WHT

BLK

VIO

BLK

WHT

YL/GN

GRY

RED

BLK

RED

ORG

RED

BLU

BLU

BLK

YEL

RED

WT/VI

WT/BU

GRY

BLK

FUEL

SHUTDOWN

SOLENOID

FUEL

PUMP

OIL

SENDER

RED

WHT

BLK

OPTIONAL

BA

TTER

Y

DISCONNECT

D+

PLUG LOCA

TION

PIN

POWER + DC

+

RELA

Y

BOARD

BO1

C1 (+12VDC)

LOCA

TION

C2 (+12VDC)

BO2

SR

T

FUE

BO3

BO4

BO5

BO6

PREHEA

T

OPEN

OPEN

OPEN

BO2 (FUEL

BO1 (ST

A

R

T

)

BOTT

OM

GR

Y

VIO

RED

YEL

POWER - DC

-

BO7

OPEN

BLK

RED

RED

OPEN

BI7

DC WIRING DIAGRAM

71

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Summary of Contents for MLT 4250

Page 1: ...OPERATING PARTS MANUAL MLT 4250 ...

Page 2: ... 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 ...

Page 3: ...WER SET UP 25 RAISING THE TOWER 26 RAISING THE TOWER WITH OPTIONAL ELECTRIC WINCH 27 LIGHTTOWER START UP 28 PRE STARTCHECKLIST 28 MANUAL STARTING OF THE GENERATOR 28 30 AUTO REMOTE STARTING OF THE GENERATOR 30 LIGHTOPERATION 31 SHUTTING DOWNTHE GENERATOR 31 LOWERING THE TOWER 32 LOWERING THE TOWER WITH OPTIONAL ELECTRIC WINCH 32 REMOVINGTHE LIGHTS FORTRANSPORTATION 33 TOWING THE TRAILER 33 TRAILER...

Page 4: ...operatinginstructionsandfamiliarizeyourselfwiththelocationandproperuseofallinstrumentsandcontrols 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 a...

Page 5: ... Always disconnect the NEGATIVE battery cable from the corresponding terminal before performing any service on the engine or other components Shut the engine down if any of the following conditions exist during operation 1 Noticeable change in engine speed 2 Loss of electrical output 3 Equipment connected to the generator overheats 4 Sparking occurs 5 Engine misfires or there is excessive engine g...

Page 6: ...afety 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...

Page 7: ...by 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 t...

Page 8: ...h 1 80 6 81 Battery Type Group Number 24 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 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 1...

Page 9: ...s set up use and service requirements Specifications are subject to change without notice 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 Voltage Selection 3 Position Switch lockable Voltage Regulation 1 VoltagesAvailable 1Ø 120 139 208 220 240 277 VoltagesAvailable 3Ø 208 220 440 480 Trailer Numb...

Page 10: ...L 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 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 EXTERIOR LOCATIONS 10 ...

Page 11: ...or remote starting 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 VOLTAGE SELECTOR SWITCH section for more information 8 VOLTAGE ADJUSTMENT RHEOSTAT Used to fine tune generator output voltage 9 CONTROL POWER SWI...

Page 12: ...ICS keypad and the STATUS 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 Toggle Switch This toggle switch powers up the control panel and the controller Fine Voltage Adjustment Screw This screw may be adjusted to set the generator output vo...

Page 13: ...us 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 Lo...

Page 14: ...ote 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 I...

Page 15: ...w 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...

Page 16: ... 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...

Page 17: ...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 com...

Page 18: ... 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 An...

Page 19: ...nstrates 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 Set...

Page 20: ...nection should 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 ...

Page 21: ...andle 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 ...

Page 22: ...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...

Page 23: ... 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 dry contact closure switch Before pressing the AUTO 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 con...

Page 24: ...instructions and warning labels supplied with the switch 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 WARNING It is strongly recommended that ONLY a licensed electrician perform any wiring an...

Page 25: ...gerjacksandrotatethem90ºuntilthespringloadedpinsnapsback into place 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 rais...

Page 26: ...ck or any of the tower sections get stuck STOP IMMEDIATELY and contact an authorized service center 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 The trailer must be leveled with the outriggers extended before raising the tower The outriggers must remain extended while the t...

Page 27: ...he 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 IMMEDIATELY and contact an authorized service center 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 direct...

Page 28: ...cked 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 ...

Page 29: ...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 PAUSE 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 Th...

Page 30: ...n 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 Starting of the Generator sections beginning on page 28 Also follow all safety warnings and information on isolating the ...

Page 31: ...inue 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 m...

Page 32: ... 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 sectio...

Page 33: ... 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 ti...

Page 34: ...tify 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 Water m...

Page 35: ...ures 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 C...

Page 36: ...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...

Page 37: ...mately 400 VAC as the light strikes induces an arc then drop and slowly rise back up to stabilize at 240 260 VAC 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 che...

Page 38: ...ER 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 COMPLETE...

Page 39: ...TRANSPORTE ANTES DE REMOLCAR O LEVANTAR EL MISMO WARNING Inside Front Panel WARNING WARNUNG ADVERTISSEMENT ADVERTENCIA DIESEL DIESEL DANGER GEFAHR PELIGRO DANGER ADVERTENCIA WARNUNG ADVERTISSEMENT WARNING WARNING WARNUNG ADVERTISSEMENT ADVERTENCIA WARNUNG ADVERTISSEMENT ADVERTENCIA WARNING WARNUNG ADVERTISSEMENT WARNING ADVERTENCIA 2 2 2 2 1 1 1 1 1 1 1 1 UNIT DECALS 39 ITEM NO PART NO QTY DESCRIP...

Page 40: ...A DE DESPRENDIMIENTO 6 CONTROLE LAS LUCES DEL REMOLQUE ABSCHLEPPINSTRUKTIONEN 1 LIRE LA NOTICE D EMPLOI 2 UTILISER UN CROCHET D ATTELAGE CONFORME AU DEBIT NOMINAL DU POIDS BRUT DE VEHICULE DU VEHICULE TRACTEUR 3 ATTACHER LA REMORQUE FERMEMENT AU VEHICULE TRACTEUR 4 ATTACHER LES CHAINES DE SURETE EN UTILISANT UNE METHODE CROISEE 5 ATTACHER LA CHAINE DE REMORQUAGE AU VEHICULE 6 VERIFIER LES LAMPES D...

Page 41: ...NE 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 STARTING THE GENERATOR DAS STARTEN DES GENERATORS COMIENZO DEL GENERADOR COMMENCEMENT DU GÉNÉRATEUR 1 TURN CONTROL SWITCH ON ENGINE ENGINE START START STOPPING THE GENERATOR DAS AUFHÖRE...

Page 42: ...42 33 1 2 31 3 7 8 3 10 4 31 6 5 9 20 32 20 15 20 16 17 18 8 7 26 2 7 8 21 20 17 20 23 24 27 28 29 30 25 22 34 35 19 14 13 12 11 MANUAL WINCH MAST ASSEMBLY ...

Page 43: ...f 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 11934B 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 ...

Page 44: ...44 43 1 2 3 1 7 4 5 17 18 18 2 3 5 6 41 40 19 39 7 20 19 14 8 10 24 18 28 26 23 39 22 21 25 41 42 38 33 27 8 10 18 18 31 32 34 35 36 37 12 29 15 14 13 12 11 9 10 8 16 30 ELECTRIC WINCH MAST ASSEMBLY ...

Page 45: ... 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 11649Z 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...

Page 46: ... 11 11 12 13 14 70 15 18 16 56 57 18 72 19 11 19 11 19 20 21 22 71 23 24 26 25 27 28 29 30 31 32 33 34 35 36 37 38 42 41 40 39 42 43 44 45 45 47 48 49 50 51 46 52 53 55 54 58 59 60 61 62 63 64 65 66 67 67 66 67 66 67 68 1 2 3 8 9 10 11 17 ...

Page 47: ... 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 Rollerbearing 33 70055 2 BearingL44643 34 12309 2 D washer 35 12310 2 Tangwasher 36 12308 2 Spindle nut ...

Page 48: ...able 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 ...

Page 49: ... 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...

Page 50: ... 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 5 8 7 9 6 5 10 1 6 MAST JUNCTION BOX ASSEMBLY HARD WIRED LIGHTS 4 3 2 11 12 ...

Page 51: ...female 7 15404 4 Cap receptaclew 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 MAST JUNCTION BOX ASSEMBLY QUICK DISCONNECT LI...

Page 52: ...ENCLOSURE ASSEMBLY 4 3 5 6 1 9 8 11 14 7 15 10 13 12 21 19 18 16 17 9 10 5 6 3 22 23 20 18 2 24 52 25 26 27 28 ...

Page 53: ...mbly 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...

Page 54: ...1 2 8 9 5 4 3 6 7 10 11 13 12 14 15 17 16 18 54 AUXILIARY OUTLET PANEL ASSEMBLY ...

Page 55: ...ck 8 18089 2 Receptacle 120 240V 50A twist lock 9 12246B 1 Weldment outlet panel 10 15215 2 Rubberbumper 11 11485B 1 Angle mountingsupport 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 weatherproof 16 65467 2 Cover receptacle 50A twist lock 17 65460 2 Cover 20 30A 240V tw...

Page 56: ...ONS 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: ...aker 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 weatherproof50A3 wire 10 65815 Receptacle 240V 50A 14 50R RV PART NUMBER 13540 Receptacle Panel 2x5 20R 1xTT 30R 1xL6 30R 2x50A 1 2 3 4 5 PART NUMBER 13893 Receptacle Panel 2x5 20R 2xTT 30R 2x14 50 6 7 ...

Page 58: ...OVAL LIGHT ASSEMBLY 33 35 3 4 1 2 6 8 5 7 11 12 10 9 8 13 14 13 21 17 19 16 18 27 8 11 8 20 21 24 25 15 22 7 17 19 16 18 23 26 32 28 31 34 30 36 29 58 ...

Page 59: ...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 Suppor...

Page 60: ...LOWER RADIATOR HOSE ENGINE COOLING ASSEMBLY 1 2 3 7 3 12 6 22 4 5 2 1 13 14 15 16 17 8 19 20 9 6 11 18 10 21 6 60 23 ...

Page 61: ...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 overflowbottle 14 60047 1 Nut M6 hx lock class 6 DIN985 15 19714 1 Cap overflowbottle 16 60014 1 Screw M6X1 0X35hxGR8 8DIN933 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...

Page 62: ...1 10 4 2 14 9 5 11 3 7 18 21 26 17 27 23 6 24 25 10 5 12 13 4 4 17 18 28 29 ENGINE ASSEMBLY 15 16 22 20 19 8 32 33 30 31 12 62 38 37 34 35 36 ...

Page 63: ...5 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 fuelshutdown 33 16205 1 Pump fuel Isuzu 4LE1 34 11040 1 Isuzu plug oil pan 35 11041...

Page 64: ...CONTROL PANEL ASSEMBLY 64 3 7 2 1 4 6 10 8 9 2 4 6 5 15 24 21 15 20 7 17 22 23 19 18 13 16 12 14 11 25 26 27 28 25 26 ...

Page 65: ...tt 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 Terminalblock 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 81...

Page 66: ...CONTROL BOX ASSEMBLY 66 7 9 9 28 9 9 7 7 7 7 10 10 10 13 16 18 4 2 1 3 6 12 15 5 5 5 8 11 11 14 17 19 20 23 26 22 25 21 24 27 29 30 33 36 32 35 31 34 ...

Page 67: ... 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 6...

Page 68: ...60156 8 Screw M5X0 8X16panhdphil 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 lugdoor 8 60043 2 Washer split lock M5 DIN127 9 60068 2 Screw 10 24X 500panphil 12630 1 Assembly lug door LUG DOOR ASSEMBLY 68 ...

Page 69: ...N 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 1 3 2 ...

Page 70: ...T1 T2 T3 T4 T5 T6 T7 T8 T9 T10 T11 T12 F F 240V BREAKER 240V BREAKER BLK 10GA BLK 10GA BLK 10GA BLK 10GA BLK RCPT 240V RCPT 240V BLK BLK BLK GRN YEL 10GA GRN YEL 10GA LT BLU 10GA LT BLU 10GA RECEPTACLE PANEL 8 4 SOOW CABLE BREAKER CIRCUIT WHT BLK RED 4 3 2 1 R4 R3 R2 R1 LIGHT SW 4 LIGHT SW 3 LIGHT SW 2 LIGHT SW 1 BLACK BLUE RED YELLOW WHITE BROWN GREEN MAST POWER CORD GRN MAST POWER CORD 4 5 6 1 2...

Page 71: ... BLK BLK F BRN SE350 VOLTAGE REGULATOR 3 LUG DOOR SW VR BLK GN YL YEL YEL YEL WHT GRY WT BU WT VI ORG BRN ORG BRN GRY ORG BLU RED ORG WHT RED BLK RED RED WHT YEL BLK RED GRN YL GN BLK BLK BLK BLK WHT BLK BRN GRN RED BLU YEL ORG VIO VIO VIO YEL ORG WHT RED RED BLU RED BLK WT VI YEL WT BU GRY BLK VIO BLK BLK RED WHT ORG YL GN VIO GRY BLU YEL BRN BR WT WHT BLK GRN BLK WHT BRN RED BLK RED YEL RED GRY ...

Page 72: ... BREAKER PART NUMBER 12399 Receptacle Panel 2x5 20R 3xL6 30R 1x50A TO GROUND TO NEUTRAL TO MAIN BREAKER PART NUMBER 12402 Receptacle Panel 2x5 20R 3xL6 20R 1x50A TO GROUND TO NEUTRAL TO MAIN BREAKER PART NUMBER 12400 Receptacle Panel 2x5 20R 3xL14 30R 1x50A ...

Page 73: ...CK RECEPTACLE 120 VOLT 30 AMP RV RECEPTACLE CIRCUIT BREAKER 50 AMP CIRCUIT BREAKER 50 AMP CIRCUIT BREAKER 30 AMP CIRCUIT BREAKER 30 AMP TO GROUND TO NEUTRAL TO MAIN BREAKER PART NUMBER 13893 Receptacle Panel 2x5 20R 2xTT 30R 2x14 50 240 VOLT 50 AMP RV RECEPTACLE 240 VOLT 50 AMP RV RECEPTACLE 240 VOLT 30 AMP TWIST LOCK RECEPTACLE 120 VOLT 30 AMP RV RECEPTACLE CIRCUIT BREAKER 50 AMP CIRCUIT BREAKER ...

Page 74: ...RS 50 AMP CIRCUIT BRN RED BRN WHT BRN WHT RED RED 2 RED 1 BLK 2 1 RED BLK RED PROX AUX RELAY 30 87 87A 85 86 PROX SWITCH BLK BLU BLK COM N O N C VIO BLK BLU TILT WINCH EXTEND WINCH N C PROX SWITCH BLK BLU BLK 86 BLK 85 BLU RELAY 87A N O COM 30 87 YEL PROX AUX UP DN UP DN RED RED BLK BLK RED BLK 74 ...

Page 75: ...MAST JUNCTION BOX WIRING DIAGRAM 75 ...

Page 76: ...REV B PART NO 13134 11 07 08 ...

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