1

NATURAL GAS / LP GAS GENERATOR

OWNER/OPERATOR’S MANUAL○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Proposition 65The engine exhaust and some of its constituentsare known by the state of California, USA tocause cancer, birth defects and otherreproductive harm.

MAGNUM PRODUCTS, INC.918 Knopf Road

Berlin, Wisconsin 54923Ph: (920) 361-4442 Fax: (920) 361-4416

1-800-926-9768Revision: Org Date: 4/06/01 Part #: 25640

MAGNUM POWER35KW / 45KW / 60KW

2

MGL12Specifications ........................................................................ 3Safety ..................................................................................... 4Preface ................................................................................... 6Controller Features ................................................................ 7

Display and Automatic Fault Shutdowns ................................................................ 7Warning Light ...................................................................... 8Resetting The Periodic Maintenance Timer ............................................................ 8

Installation .............................................................................. 9Electrical Wiring Procedure ............................................... 10

Typical Installation of Generatorand Utility Power Components ....................................... 10Generator and Utility Power toTransfer Switch Diagram ................................................ 11Voltage Connection Diagram .......................................... 11

Fuel Supply to Engine Information ..................................... 12Installing The Gas Fuel System ......................................... 12

Engine Serial # _________________

Engine Model # _________________

table of contents○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Fuel-To-Engine Application ................................................... 13Natural Gas Application ................................................. 13L.P. (Propane) Gas Application ...................................... 14

Operation .............................................................................. 15Prestart Checks ................................................................... 15Start Functions ................................................................... 15Controller Resetting Procedure .......................................... 15Manual Start and Transfer ................................................. 15Manual Retransfer and Shutdown ...................................... 16Automatic Operation ......................................................... 17Automatic Operating Sequence ......................................... 17Battery ............................................................................... 17

Storage Instructions ............................................................. 18Cooling .................................................................................. 19Troubleshooting .................................................................... 20Service Schedule ................................................................. 22Wiring Diagrams ................................................................... 23Exploded View of Control Box and Parts List ........................... 25Exploded View of Generator Set and Parts List ....................... 26

3

Generator MGL35 MGL45 MGL60L P Gas Rated MaximumPower Capacity (Watts)Standby / Continuous 35,000 / 34,000 40,500 / 36,000 N/ANatural Gas Rated MaximumPower Capacity (Watts)Standby / Continuous 33,000 / 29,400 36,000 / 32,000 N/ARated Voltage (1 phase) 120/240 V 120/240 V 120/240 VRated Maximum LoadCurrent @ 120/240 V 316/158 A 336/168A N/ARotor and Stator insulation Class “F” Class “F” Class “F”Rated AC Frequency 60 Hz @ 60 Hz @ 60 Hz @

1800 RPM 1800 RPM 1800 RPMTransfer Switch Amperage 200 A, 200 A,Rating 240 V 240 V N/ABreaker Size 200A 200A N/A

EngineMake General Motors General Motors General MotorsModel 4.3L Vortec 4.3L Vortec 5.7 VortecType of Engine 4-Cycle, 4-Cycle, 4-Cycle,

Liquid Cooled Liquid Cooled Liquid CooledNumber of Cylinders 6 6 8Displacement 4.3 Liter 4.3 Liter 5.7 LiterValve Arrangement Overhead Valve Overhead Valve Overhead ValveIgnition System Solid State Solid State Solid StateStarter 12 V DC 12 V DC 12 V DCAir Cleaner Paper Type Paper Type Paper TypeOil Filter Full Flow Full Flow Full Flow

Spin-on Spin-on Spin-onCrankcase Oil Capacity 5.0 U.S. Quarts 5.0 U.S. Quarts 7.0 U.S. Quarts(Consult engine operatorsmanual for oil recommendations)Thermostat Temperature Temperature Temperature

Activated Activated Activated

Generator Dimensions (All Models) Minimum Battery Recommendations* (All Models)Length - 61.5 Inches (156.2 cm) Voltage - 12 Cold Cranking Amps (CCA) - 550Width - 32 Inches (81.3 cm) Group - 56 Amp-Hour Capacity - 90Height - 38 Inches (96.5 cm) * Use a 750 CCA battery when operating in

temperatures below 32° F (0° C).

1specifications

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

4

The following symbols are used throughout thismanual. Follow listed instructions to ensure your safety.

Indicates an imminently hazardous situation which, ifnot avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if notavoided, could result in death or serious injury.

Indicates a potentially hazardous situation exists which,if not avoided, may result in minor or moderate injury orproduct damage.

Indicates operation or maintenance information which ishelpful to improve performance or operation.

2safety

Magnum Products Inc. recommends that a trained andlicensed professional perform all electrical wiring andtesting functions and all fuel connections. Installationshould be in compliance with the United States Na-tional Electric Code (NEC), state and local codes andOccupational Safety and Health Association (OSHA).

Read this manual carefully. Know your equipment.Consider applications limitations and potential hazardsspecific to your unit.

This equipment is designed for specific applications.Do not modify or use for any application other thanwhich it was designed.

The following Safety precautions apply wheneverusing, storing or servicing Magnum Generators or theirengines to reduce the possibility of personal injury.Overlooking or ignoring these precautions can lead topersonal injury or product damage.

ELECTROCUTION � FLASH HAZARD1. Turn off utility power and turn off the generator to

prevent electrocution before servicing.2. Ensure that the unit is properly grounded.3. Move the generator main circuit breaker to the “OFF”

position when servicing or troubleshooting the unit.4. The output voltage of the generator can cause a

fatal electric shock. Avoid contact with any alter-nating current wiring.

5. Use extreme caution when servicing this equip-ment in damp or wet conditions.

6. Do not remove control box cover when the engineis running. Exposed live electrical terminals cancause electrical shock.

7. This unit is a single-phase stand-by electricalsource. Check your electrical requirements beforeinstalling.

8. Use a ground fault circuit interruptor (GFCI) indamp or highly conductive areas and constructionsites to prevent electrical shock.

CARBON MONOXIDEHAZARD

1. Engine exhaust contains carbon monoxide, adeadly, odorless, invisible gas, which, if inhaled,causes nausea, fainting or death.

2. Never allow snow, leaves, or other debris to blockair or exhaust openings to generator.

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

5

3. Operate only in well-ventilated areas.4. Never operate indoors without exhaust system to

the outside.5. Ensure that exhaust cannot seep into enclosed rooms.

1. Improper installation can damage your electricalsystem and cause property damage, serious injuryor death.

2. A potential for fire or explosion always exists whenusing natural gas or L.P. (Propane) gas.

3. Ensure that all connections, hoses, and clampsare secure and free of leaks.

4. Turn fuel shut-off valves to the “OFF” position whenthe unit is serviced or if there is a strong odor offuel, call fuel supplier from a remote location.

5. Never smoke or use open flames near the unit, fuelstorage tank or battery.

6. Follow all codes pertaining to installation andoperation of fuel storage tanks.

7. Keep a fire extinguisher close by. Consult your firedepartment for best type of extinguisher to use.

8. Batteries contain sulfuric acid, which can causesevere injury or death. Sulfuric acid can causepermanent eye damage, burn flesh, and eat holesin clothing. Protective eye wear and clothing arenecessary when working on or around the battery. Ifacid splashes in or around the eyes, flush withwater for 15 minutes. Seek immediate medical at-tention.

After operating, allow unit to cool before touching com-ponents.

BURN HAZARD

EXPLOSION �FIRE HAZARD

ACCIDENTAL STARTING

Turn the main circuit breaker to the “OFF” positionand remove the battery cables from the battery(negative first) before performing any service work.When finished, reconnect the battery cables (positivefirst), then turn the main circuit breaker to the “ON”position.

Your generator must never be operated under thefollowing conditions:

a. Noticeable change in engine speedb. Loss of electrical outputc. Equipment connected to the generator

overheatsd. Sparking occurse. Engine misfiresf. Excessive generator vibrationg. Operating on a combustible surface

● Don’t wear loose clothing, jewelry, etc. that may becaught in rotating parts.

● Don’t insert objects through the venting slots, evenif the generator is not operating.

● Follow all Safety Instructions.● Never operate without protective covers or hous-

ings or with broken or missing parts. ContactMagnum Products Inc. for replacements.

● Never operate generator when ambient tempera-ture is over 110° F (43° C).

Prolonged exposure to sound levels inexcess of 85DBA can cause permanenthearing loss. Wear hearing protectionwhen near an operating generator. Donot operate without a functional exhaustsystem.

● Keep the generator clean and free of oil, mud, andother foreign matter.

● Make sure the engine and generator reach operat-ing speed before connecting any electrical load.

● Cabinet should be locked at all times.

6

We all depend on electric power in our daily lives. Itmakes our lives easier and more enjoyable and isnormally so readily available that we take it forgranted. Whether we are at home, work, shopping orout for entertainment, we rely on electrical power toallow us to do the things we want. At times, though,certain circumstances occur to disrupt this flow ofelectricity. Any number of problems can cause thistype of disruption and it is at this time that you needthe reliable power of Magnum Power Generators.Your home or business will be safe-guarded fromdamage or loss due to a sudden and/or prolongedpower loss.

Your Magnum Power Generator will sense the loss ofutility supplied electrical power and automaticallyprovide your premises with the power you need. Whenutility power returns, the generator will transfer back tothat supply and await the next time it is needed. Thepeace of mind and feeling of security provided isapparent whether you are there or not.

YOU CAN REST ASSURED WITH MAGNUM POWERGENERATORS!

The generator sets referred to in this manual are veryhigh quality, electric power sources. They are enginedriven, emergency systems intended to supply tem-porary electric power to lights, appliances, power tools,and other industrial, commercial and home products.

Thoroughly study the safety and operating instructions

to ensure you are acquainted with the generator set.Proper preparation, operation and maintenance willresult in safe operation, best performance and genera-tor set longevity.

Refer to the Service Schedule chart for maintenancetimes and to the Troubleshooting chart in this manualfor diagnosing problems.

These generator sets are constantly upgraded. Specifi-cations described in this manual are subject to changewithout prior notice.

Before using, determine the suitability of the product forits intended use. Magnum is not responsible for themisuse of the generator.

Refer to the separate engine manufacturer’s manual forrecommended engine oil, filters, spark plugs, etc.

These generator sets are powered by liquid cooledengines. This liquid cooling works in conjunction with airdrawn into the enclosure, across the engine andexhausted to keep both generator and engine at theproper operating temperature.

In climates where the temperature drops below 40° F(4° C), a block heater must be installed on the engine.Contact dealer for details. Failure to do so can result inpoor performance or component failure.

3preface○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

7

The generator controller has four essential features:

1. A start control switch [A] that enables automatic(stand-by) starting – UP position, manual starting –DOWN position, or OFF ("O") – middle position.

2. A line circuit breaker [B] has been sized for genera-tor output in the event of an overload or a shortcircuit. If the generator set circuit breaker trips,reduce the load, and switch the breaker back to theON position. The generator set will continue to runeven if the circuit breaker is in the OFF position, butthere will be no output voltage.

3. A monitoring system that incorporates a display (C)to constantly indicate various generator and enginefunctions. Also, holding the switch (D) below thedisplay in the UP position will show engine runninghours, engine sender condition, periodic mainte-nance time, and engine fault set points. Holding theswitch DOWN will "lock in" a specific display.

4. A fault shutdown condition that will cause theengine to stop running because of a sensedproblem. There is also a warning light [E] thatilluminates as a pre-alarm for a potential faultcondition.

Any tampering or adjustments to the controller cancause serious injury or death.

DISPLAY AND AUTOMATIC FAULTSHUTDOWNS

If the generator set fails to start after five attempts, theovercrank shutdown will be activated. If the generator isin an overspeed or underspeed mode, the shutdown willbe activated. If there is a current overload, the shutdownwill be activated. The engine is also equipped with an oilpressure sender that will activate the low oil pressureshutdown if the oil pressure drops too low, and a watertemperature sender that will activate a high temperatureshutdown if the engine temperature exceeds safe level.These errors are indicated on the display.

Generator information is shown on the top line of thedisplay and engine information is shown on the bottomline of the display. Both are scrolled continuously whilethe generator is operating.

4controller features

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

8

The generator features are:

● Volts – Displays the AC output voltage beingproduced by the generator.

● Phase – Indicates which phase is currently beingdisplayed.

● Amps – Displays the AC output amperage pro-duced by the generator. If the generator is operatingat no-load, output amperage will display "0".

● Hertz – Displays output frequency. The readingshould be approximately 60 Hz under a no-loadcondition. An underspeed fault shutdown will occurafter 15 seconds at 50 Hz (1500 RPM). Anoverspeed fault shutdown will occur at 75 Hz (2250RPM).

The engine features are:

● Oil Pressure – Displays engine oil pressure. Thegauge registers oil pressure between 0-100 PSI.Normal operating pressure is between 40-60 PSI. Ifoil pressure drops below 15 PSI for more than fiveseconds, a fault shutdown will occur.

● Fuel – Fuel level will not be indicated.

● Temperature – Displays the temperature of theengine coolant. If the temperature goes above 240°F for more than five seconds, a fault shutdown willoccur.

● Battery – This display monitors engine batteryvoltage. Normal voltage is between 13.5V-14.5V.

A fault shutdown will occur if an overcrank conditionarises. This will be after the fifth 10-second crank/restcycle.

Current load is also monitored. The values are internallyprogrammed at the factory and are different for eachgenerator model. A fault shutdown will occur when anoverload condition is sensed. Determine and eliminatethe cause by checking all loads at the generator tomake sure they do not exceed the generator powerrating.

The display will show coolant sender and oil pressuresender fault. It will also show "Time to Service"information. A shut down will not occur under theseconditions.

After a fault shutdown, the generator operating systemmust be reset. Place the engine start switch in the OFF("0") position, then go back to the AUTO or MANUALmode.

WARNING LIGHT

The amber warning light will turn on prior to a faultcondition occurring. This calls attention to a potentialfault condition. When the warning light illuminates, theLCD will start blinking to indicate which function isapproaching its fault value.The pre-alarm set points are:

● High Temperature – 235° F.

● Low Temperature – 70° F.

● Low Oil Pressure – 20 PSI.

● Fuel Level – N/A.

● Time to Service – 0 hours.

● Sender Failure – Engine coolant and oil pressuresenders.

RESETTING THE PERIODICMAINTENANCE TIMER

After maintenance has been performed on the genera-tor set, it is necessary to reset the timer.

● If the timer is at "0", hold the switch below the LCDto the UP position until the "Time to Service" resetsto 250 hours.

● If the service time is greater than "0", (maintenancewas performed prior to the timer running out) holdthe switch up for 30 seconds to reset the timer to250 hours.

9

This generator set may have been transported bycommon carrier truck to dealer destinations. It ispossible that hardware and/or electrical connectionsmay have become loosened. As part of original installa-tion, always include the following:

1. Check all outside and inside hardware for tightness.Tighten as necessary.

2. Check the termination points of all wiring in genera-tor control panel, engine wiring, and transfer switch.Tighten or repair as necessary.

3. Normally, loose wires can be found by manuallypulling wires to the left and right of the connectionpoint.

The Magnum Power 12KW, 18KW and 23KW standbygenerators were not designed as a do-it-yourselfinstallation project.

It is equally important to carefully plan the installation inconjunction with qualified installation professionals.Take into consideration:

1. Location of the generator indoor or outdoor.(Proper exhaust ventilation is necessary. Place inan area that is not prone to flooding.)

2. Mount the generator on a solid foundation. A 3 in.cement slab is recommended along with anchoringthe unit to the foundation with bolts. Allow 3 ft ofclearance around the entire generator for mainte-nance, service, and exhaust gases.

3. The location must provide adequate airflow forengine and generator cooling. To prevent damageto the generator set caused by overheating, ensurethat all air inlets and outlets are free from obstruc-tion at all times.

In climates where the temperature drops below 40° F(4° C), a block heater must be installed on the engine.Failure to do so can result in poor performance orcomponent failure.

4. The transfer switch must be sized to handle theampere rating.

5. The generator’s voltage and phase ratings must bein accordance with the utility supply and load circuitvoltage and phase rating.

6. Never install the generator on combustible material.If the installation location is made of combustiblematerial, the qualified installation professional musttake the necessary measures to insulate thegenerator.

7. Decide what the critical loads are, and choose theproper isolation method.

8. Choose which fuel type/source to use for thegenerator. Locate the generator as close aspossible to that type and source. (Check all fuellines for leaks).

5installation

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

10

(A) Ground stake and ground wire for separatelyderived systems where there is no direct generatorneutral connection to the utility company neutral.Furnished by the installer.

For a system that does not have utility power (sepa-rately derived), the generator neutral must be bonded tothe ground at the generator set.

(B) Normal utility power meter and power input tonormal distribution panel.

(C) Original electric distribution panel. This suppliespower for all non-emergency loads plus the emergencyloads connected to the utility side of the transfer switch.

(D) Separate smaller distribution panel for the emer-gency loads that were taken from the original distribu-tion panel. Furnished by the installer.

(E) Transfer switch with UL 1008 listing, either 100 amp oroptional 200 amp size, with remote start – stop function.

(F) Generator set output wires in conduit.

(G) Control wires in conduit.

Do not install the 12VDC battery until all the other wiringprocedures have been completed.

Do not turn on utility power until all electrical wiring hasbeen completed and the battery has been properlyinstalled and the battery cables have been connected(positive first, then negative).

Use a ground fault circuit interrupter (GFCI) in damp orhighly conductive areas and construction sites toprevent electrical shock.

Electrical wiring should be in compliance with the UnitedStates National Electrical Code (NEC), state and localcodes and Occupational Safety and Health Association(OSHA).

ELECTRICAL WIRING PROCEDURE

Typical Installation of Generator and Utility Power Components

11

Generator and Utility Power to Transfer Switch Diagram

(A) Generator power(B) Utility power (Service entrance)(C) Electrical load(D) Transfer switch(E) Utility power to switch hook-up and test point (U1)(F) Utility power to switch hook-up and test point (U2)(G) Neutral (Ground)(H) Generator power to switch hook-up and test point

(E1)(I) Generator power to switch hook-up and test point

(E2)(J) Remote start(K) Remote annunciator(L) Power wires for trickle charger and block heater

Refer to transfer switch manual for specific installation.

Line Side – To Get Load side - Use

120 VAC @ 60 Hz L1-L0

120 VAC @ 60 Hz L2-L0

240 VAC @ 60 Hz L1-L2

Never connect leads L1 and L2 together on the lineside.

Voltage Connection Diagram

12

FUEL SUPPLY TO ENGINE INFORMATION

Fuel line diameter depends on the amount of fuelneeded to run an engine-generator at full load and thedistance the fuel must be moved. Refer to specificationTable A for fuel consumption. Table B shows pipe sizefor L. P. (Propane) gas. Table C shows pipe size fornatural gas.

Table A: Fuel ConsumptionUse horsepower (H. P.) to find fuel consumption. Then,match that figure up with the length of fuel pipe.

Example: An MGL18 generator with natural gas fuelwhich is located 100 feet from fuel source. Locate fuelconsumption in Table A for match – MGL18 (= 217 cu.ft.). Find closest fuel consumption in Table C that isgreater than 217 cu. ft. in 100 foot column (= 400 cu.ft.). Find the pipe diameter for this amount of fuel on leftside of Table C (= 1-1/4 in.).

Table B: L. P. (Propane) Gas PipeSizingMaximum pipe capacity in thousands of BTU per hourfor a gas pressure drop of 0.5 inches of water column

(14-16 inches water column gas pressure at engine inlet).Table C: Natural Gas Pipe SizingMaximum pipe capacity in cubic feet of gas per hour for0.5 psi or less, and a pressure drop of 0.5 inches ofwater column based on a 0.60 specific gravity gas (14-16 inches water column gas pressure at engine inlet).

INSTALLING THE GAS FUEL SYSTEMIn no way should the following information be under-stood to conflict with existing local, state, or national fuelgas codes which may differ from the information in thismanual. Contact your local fuel supplier for specificsizing information.

Cast iron pipe fittings such as main fuel feed lines,elbows, tees, couplings, etc. shall be used. Aluminumtubing shall not be used in exterior locations or where itis in contact with masonry, plaster walls or insulation.

TABLE A: FUEL CONSUMPTION � THOUSANDS OF BTU PER HOUR / CUBIC FEET PER HOUR

Unit MGL 35 MGL 45 MGL 60

L. P. (Propane) gas

Natural gas

TABLE B: L. P. (PROPANE) GAS PIPE SIZING IN THOUSANDS OF BTU PER HOUR

Length (FT.) 10 20 30 40 50 60 70 80 90 100 125 150

DIA (Nominal

iron pipe sizes)

1/2" 291 200 161 137 122 110 102 94 87 84 74 67

3/4" 608 418 336 287 255 231 212 198 185 175 155 141

1" 1146 788 632 541 480 435 400 372 348 330 292 265

1-1/4" 2353 1617 1299 1111 985 892 821 764 717 677 600 544

1-1/2" 3526 2423 1946 1685 1476 1337 1230 1144 1074 1014 899 816

2" 6789 4666 3747 3207 2842 2575 2368 2204 2068 1954 1731 1589

TABLE C: NATURAL GAS PIPE SIZING IN CUBIC FEET PER HOUR

Length (FT.) 10 20 30 40 50 60 70 80 90 100 125 150

DIA (Nominal

iron pipe sizes)

1/2" 175 120 97 82 73 66 61

3/4" 300 250 200 170 151 138 125 118 110 103 93 84

1" 680 465 375 320 285 260 240 220 205 195 175 160

1-1/4" 1400 950 770 660 580 530 490 460 430 400 360 325

1-1/2" 2100 1460 1180 990 900 810 750 690 650 620 550 500

1-3/4" 3230 2246 1815 1523 1385 1246 1154 1062 1000 954 846 769

2" 4969 3455 2792 2343 2132 1917 1775 1634 1539 1468 1302 1183

13

Fuel-to-Engine ApplicationA specific assembly of components for either natural orLP (Propane) gas is required for the generator set.Certain parts and their positioning must change to adaptto the difference in fuels. For application, refer to thedrawings on pages 13 and 14.

Natural Gas Application

(A) Inlet nipple (in. NPT x in.) – operating range; 14-16 inches water column gas pressure ............................. 25700(B) Elbow – 90° (in. NPT) .............................................................................................................................. 25495(C) Fuel solenoid valve ................................................................................................................................. 25058(D) Fuel Assy Bracket ................................................................................................................................... 25695(E) “U” Bolt (1/4 in. x 2.0 in.) .......................................................................................................................... 60367(F) Regulator

*Install with valve upward** Engine side port to pull 5 inches water column gas pressure ............................................................... 25520

(G) Elbow – 90° (3/4 in. NPT) ......................................................................................................................... 25110(H) Hose fitting (3/4 in. NPT x 1 in.) ............................................................................................................... 25496

H

G

F

A

D

E

C

A

B

A

14

L.P. (Propane) Gas Application

(A) Inlet nipple (in. NPT x in.) – operating range; 14-16 inches water column gas pressure ............................. 25700(B) Elbow – 90° (in. NPT) .............................................................................................................................. 25495(C) Fuel solenoid valve ................................................................................................................................. 25058(D) Fuel Assy Bracket ................................................................................................................................... 25695(E) “U” Bolt (1/4 in. x 2.0 in.) ......................................................................................................................... 60367(F) Regulator

*Install with valve downward and the spring removed**Engine side port to pull – 1 (negative) inch water column gas pressure (slight vacuum) ........................ 25520

(G) Elbow – 90° (3/4 in. NPT) ......................................................................................................................... 25110(H) Hose fitting (3/4 in NPT x 1 in.) ................................................................................................................ 25496

H

G

F

E

A

A

A

B

D

C

15

PRESTART CHECKS

Never operate generator when ambient temperature isover 110° F (43° C).

Before starting the generator, perform the followingprocedures to ensure peak performance:

1. Check engine oil level. It should be at or near thefull mark.

2. Visually inspect engine, generator, and exhaustsystem to ensure they are free from any obstruc-tions or debris that may block air flow or possiblyignite from contact with hot engine components.The engine compartment should be free of anyobjects foreign to its design.

3. Inspect the battery cables to ensure they are tightlyconnected and free of corrosion.

4. Maintain a clean air filter to prevent contaminantsfrom entering the engine.

START FUNCTIONS

AUTO/OFF-RESET/MANUAL SWITCH: Set the toggleswitch to the "AUTO" position for automatic operation.Set toggle switch to the "MANUAL" position to crankand start the generator engine. Set switch to "OFF"position ("O") to shut down an operating engine.Automatic operation will not be possible when "OFF" or"MANUAL" are selected.

With this switch set to "AUTO", the engine can crankand start suddenly without warning. Such automaticstart up normally occurs when utility source voltagedrops below a preset level. To prevent possible injurythat might be caused by such sudden starts, set switchto "OFF" ("O") before working on or around the unit.

Fault display: Use this readout to help troubleshoot.

The display will function with the generator placedin the AUTO position.

CONTROLLER RESETTING PROCEDURE

The following procedure must be used to reset thecontroller after a fault condition.

1. Place the toggle switch in the "OFF/RESET"position.

2. Switch the circuit breaker to the "OFF" position, anddisconnect the load.

3. Correct the fault condition.4. Place the toggle switch in the "MANUAL" or

"AUTO" position for startup.

MANUAL START AND TRANSFER

Place the AUTO/OFF-RESET/MANUAL switch in the"MANUAL" position. The engine controller will begin thestarting procedure detailed above.If the generator does not start, return the switch to theOFF-RESET position for the duration of 10 secondsand return the switch to the "MANUAL" position.If the generator completes a second starting cyclewithout successfully starting, refer to the troubleshootingsection of this manual.

To start the engine manually and transfer load circuits tothe EMERGENCY (standby) power source manually,proceed as follows:

1. Shut off utility power by putting the main line circuitbreaker in the "OFF" position.

Do not try MANUAL operation of thetransfer switch until all power suppliedto the switch has been positivelyturned "OFF". Failure to turn OFF thesupplied power may result in an

extremely dangerous and potentially lethal electricalshock.

2. Check for proper manual operation of the automatictransfer switch using a transfer switch handle.

See Generator and Utility Power to Transfer SwitchDiagram for voltage tests points.

6operation

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

16

3. After verification that transfer switch operatesmanually, actuate the transfer switch main contactsto the UTILITY position, i.e., LOAD terminalsconnected to the utility power supply.

4. Turn ON the utility power supply to the transferswitch with whatever means provided (normally theutility main line circuit breaker). Use an AC voltme-ter to verify that correct load voltage is available attransfer switch main contact, terminal lugs U1 (E)and U2 (F) and ground at neutral post (G). Voltagefor 120 V output should be 108-132V. Voltage for240 V output should be 216-264V.

5. Set the AUTO/OFF-RESET/MANUAL switch to the"OFF" position on the generator control panel.

6. Turn OFF the utility power supply to the transferswitch.

7. Set the generator’s main circuit breaker to the"OFF" position.

8. Turn off all electrical loads. Initial testing andadjustment should be conducted with the generatorat no load.

9. Set the AUTO/OFF-RESET/MANUAL switch to the"MANUAL" position to start the generator enginemanually. Let the unit stabilize and warm up for afew minutes.

10. Set the main circuit breaker on the generator to the"ON" position.

11. Using an accurate AC voltmeter, verify that correctrated voltage and frequency are being supplied totransfer switch terminals E1 (H), E2 (I), and neutralground (G).

a. Do not proceed until generator output fre-quency and voltage are correct.

b. If AC frequency is not within 59-61 Hz at no-load, contact authorized service technician.

DO NOT attempt to adjust the governor. Only qualifiedservice facilities should adjust the governor. ExcessivelyHIGH operating speeds are dangerous and increasethe risk of personal injury. LOW speeds impose a heavyload on the engine when adequate engine power is notavailable and may shorten engine life. Correct ratedfrequency and AC voltage are supplied only at theproper governed speed. Incorrect AC frequency and/orvoltage may damage some connected electrical loaddevices. ONLY QUALIFIED SERVICE TECHNICIANSSHOULD ADJUST THE ENGINE GOVERNOR.

On units connected for 240 volts, 1 phase output, line-to-line voltage at 60 Hz should be 240 volts ±10%. Takethese initial readings with the generator running at no-load.

DO NOT PROCEED UNTIL NO LOAD FREQUENCYAND VOLTAGE ARE CORRECT.

12. Verify that all utility power has been turned "OFF"to the transfer switch. Then, manually actuate thetransfer switch main contacts to the "STANDBY"position, i.e., LOAD connected to the GENERA-TOR.

13. Turn ON electrical loads that almost equal thegenerator’s wattage amperage capacity. With anAC frequency meter, check frequency at transferswitch terminals E1 (H) and E2 (I). With genera-tor under load, frequency should not drop below58 Hz.

14. Let the generator run under load for at least20-30 minutes. Check for unusual vibration,noise, high temperature, and other indications ofabnormal operation.

MANUAL RETRANSFER ANDSHUT DOWN

Electrical loads may be retransferred back to the utilitypower and the generator can be shutdown as follows:

1. Verify that utility power supply to the transfer switchhas been positively turned "OFF".

2. Set the generator’s main circuit breaker to its "OFF"position.

3. Let the generator engine run at no-load for severalminutes to stabilize internal unit temperatures.

4. On the generator control panel, set the AUTO/OFF-RESET/MANUAL switch to "OFF". Wait for engineto come to a complete stop.

5. With the manual transfer handle, move the switch’smain contact back to the utility power position. Thisreconnects the utility power supply.

6. Turn ON the utility power supply to the TransferSwitch. The utility power source now powers theloads.

17

AUTOMATIC OPERATION

To set the system for fully automatic operation:

1. Check that load circuits are connected to the utilitypower supply.

2. Set the AUTO/OFF-RESET/MANUAL switch to the"AUTO" position.

3. Set the generator main circuit breaker to its "ON"position.

When the controller receives the start command fromthe transfer switch, the starting procedure will begin. Ifthe generator fails to start, the transfer switch will stayconnected to utility power. Refer to the troubleshootingsection of this manual for more information.

The controller will start the engine if either:

● The control switch is in the MANUAL position.

● The control switch is in the "AUTO" position and theremote start contacts are closed.

If the engine is already running, the start attempt will becancelled. The controller will attempt to start the engineby engaging the fuel solenoid and the starter relay. Thespeed input is monitored to determine if the enginestarts.

When running speed is detected, the starter relay isdisengaged and normal monitoring is begun after thestartup delay period of 10 seconds. This delay allows oilpressure to be established and allows the engine speedto stabilize.

Cranking will continue for 15 seconds if the engine doesnot start. After this time, the fuel solenoid and the starterrelay are disengaged for a rest period of 10 seconds.After the rest period, another crank attemptis performed.

After five unsuccessful attempts, the controller will issuean OVERCRANK shutdown fault. If this occurs followthe guidelines in the troubleshooting section of thismanual.

AUTOMATIC OPERATING SEQUENCE

The sequence of automatic operation is brieflydescribed as follows:

1. If the utility source drops below a preset level adelay timer starts.

2. After the delay time, the transfer switch sends asignal to the engine remote contacts to start.

The delay timer is provided to override momentaryoutages and prevent nuisance starting of thegenerator.

3. The transfer switch senses the voltage of theemergency source. When the emergency sourcereaches a preset level, transfer delay timing begins.When this time is completed, the load circuits aretransfered to the emergency source.

4. If the utility source voltage is restored, above thepreset level, the transfer switch monitors thevoltage for a period of time. After this time theswitch retransfers load circuits back to the utilitypower source.

5. After load circuits are retransfered, the engine willgo through its cool down procedure before shuttingdown.

BATTERY

Use a 12-volt battery with a minimum of 450 coldcranking amps for the generator. The climate will be amajor factor in deciding the appropriate battery. If thetemperature dips below 0° F for extended lengths oftime, a more powerful battery may be necessary.Consult your local dealer/distributor for assistance.

If the generator set is not run on a regular basis, use anexternal battery charger to sustain full charge. Followthe safety precautions in the beginning of this manualwhen servicing the battery. Battery gases can cause anexplosion, which can cause severe injury or death.

Take extreme care when removing and replacingbattery terminals. Reversed connections can causesevere damage to the generator controller.

18

Storage procedure for the engine:

1. Run the engine to warm up the oil.2. Drain oil from the crankcase.3. Refill with fresh oil of recommended grade.4. Remove spark plugs and pour 1oz of engine oil into

cylinders.5. Replace spark plugs and crank slowly to distribute

oil.6. Clean dirt and chaff from cylinders, cylinder head

fins, blower housing, rotating screen and muffler.7. Start generator, shut off fuel supply, and let the

engine stop from lack of fuel.8. Disconnect fuel source and cap fuel inlet.

Enclosure and Generator preparation:

● Allow the generator to be completely cooled.● Disconnect battery cables (negative first), clean,

and wrap with non-absorbent adhesive tape.● Remove dirt and dust from outside and inside of

cabinet.● Remove any foreign objects.● Store in a clean and dry area, but NOT near

anything which uses a pilot light or any device thatcan create a spark.

● Place a tarp over the entire unit to prevent dust anddirt build-up.

7storage instructions○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

19

These generator sets are powered by liquid cooledengines. The system is thermostatically controlled whichallows liquid flow through the engine when the tempera-ture reaches 165°-175° F (74°-80° C). It is imperativefor proper operation and longevity that the coolingsystem be maintained according to the enginemanufacturer’s manual and the maintenance chart inthis manual. The engine draws in air from the generatorside, and draws the air across the engine, exhaust,generator end, and out the radiator end of the enclo-sure. The enclosure for the genset was designed totake in and blow out a specific amount of air.

Any obstructions to the airflow can cause severe engineand generator damage from overheating.

In climates where the temperature drops below 40° F(4° C), a block heater must be installed on the engine.Contact dealer for details. Failure to do so can result inpoor performance or component failure.

8cooling

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

20

When problems arise with the generator set, don’toverlook the obvious solutions. More times than not, asimple solution will fix the problem. If you are unable tocorrect the problem call your local dealer/distributor forassistance.

9troubleshooting○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Problem Possible Cause Source/Solution

Generator does not Poor battery connections or Inspect cable connections for corrosion andturn over. cables are reversed. correct placement.

Controller fuse is blown. Inspect fuse and replace if necessary.

AUTO/OFF-RESET/MANUAL Place switch in desired position.Switch is off.

Defective AUTO/OFF-RESET/ Perform a function test.MANUAL Switch.

Generator turns Fuel source. Inspect fuel lines to ensure the generatorover, but does not set is receiving the appropriate level of fuelstart, or starts pressure. Check to ensure that thedifficulties. correct fuel source has been supplied.

Primary and Secondary Perform a function test.Regulators.

Weak Battery. Check voltage and recharge or replace.

Low oil pressure shut down. Check oil level and pressure. If both are within(LCD will display) the recommended levels, check controller for

function.

Fouled spark plugs or loose Inspect spark plugs, and replace if necessary.connection. Check for tight connection to spark plug wire.

Engine timing off. Service engine.

No AC output from Main Breaker in "OFF" position. Place breaker in the "ON" position.generator.

Main Breaker tripping from overload. Reduce the load on the generator.

Main Breaker tripping from a Find the short in the system and correct.short circuit.

Voltage Regulator Check fuse in voltage regulator.Check voltage regulator.

Generator problem. Contact your local dealer or distributorfor assistance.

21

Problem Possible Cause Source/Solution

High output Faulty Voltage Regulator Replace voltage regulator.(Frequency)

Generator problem. Contact your local dealer or distributor forassistance.

Governor Setting Contact your local dealer or distributor forassistance.

Low output Overloading generator. Reduce the load on the generator.(Frequency)

Faulty Voltage Regulator Replace voltage regulator.

Generator problem. Contact your local dealer or distributor forassistance.

Governor Setting Contact your local dealer or distributor forassistance.

Generator stops No Fuel. Check fuel source.suddenly.

Low oil pressure shutdown. Check oil level and pressure.(LED will be steady Red)

Over temp. shutdown Check coolant level and thermostat.

Blown Controller Fuse. Replace fuse. If it blows again, inspectcontroller for faults.

Overspeed shutdown. Place the controller in the "OFF" position for(LED will be steady Red) 30 seconds and return to desired position.

If the shut down occurs again, check the governor,mag pick-up, fuel supply and controller.

Engine Problems.Service engine.

DUSTY OR DIRTY OPERATINGCONDITIONSUnder these conditions, use dry compressed air to blowout the generator. With the generator set running, directair through the slots at the engine end of the generatorset.

ENGINE SERVICEPerform routine maintenance at specified intervals asdocumented in the supplied engine manufacturer’smanual.

TUNE-UPSHave the generator set tuned-up by an authorized

22

distributor. Tune-ups will improve performance andmaintain reliability.

Perform recommended service at every scheduledinterval to ensure satisfactory operation. If roughoperation, lack of power, or excessive oil use isapparent, have an authorized distributor service thegenerator set. Immediate action can prevent serious problems.

SERVICE SCHEDULE

Component Frequency

5 Hours 50 Hours 250 Hours Everyor Daily Weekly or or 2 Years

Annually AnnuallyFuel

Inspect flexible lines and connections ●

Check solenoid valve operation ●

CoolingAir cleaner ●

Louvers ●

Exhaust SystemInspect Insulation ●

Check Muffler bracket ●

Inspect Muffler box for fire hazards ●

Engine (See manufacturer’s manual)Check oil level ●

Change oil * ●

Change oil filter * ● ▲▲▲▲▲Change air cleaning cartridge ● ■■■■■Clean cooling system** ● ■■■■■Replace or clean spark plugs ●

Electrical SystemInspect battery and battery tray(Not supplied with unit.) ●

Clean and tighten battery terminals ●

▲▲▲▲▲ Change oil every 125 hours when operating under heavy load or in high temperatures.

■■■■■ Clean more often under dusty conditions or when airborne debris is present. Replace air cleaner parts ifexcessively dirty.

** Flush cooling system every 2 years.

* Change oil after first 8 hours, then after every 250 hours or annually.

10service schedule○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

23

11wiring diagrams

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

1 2 3 45 6 7 8

1 2 34 5 6

1 2 3 4 657 8 9 10 1211

ELEC. GOVERNORSPEED CONTROL

RED

VIO/Y

RED

RED

ORG/W

WHT

RED

YEL

BLK

CLR

CLR

BLK

GR

N/Y

TAN

/W

WH

T

WH

T

BLK

BLK

BLK

BLK

BLK

BLU

/W

WH

T

YEL

YEL

RED

RED

RED

RED

RED

BLK

BLKYEL

VIO

GRY

VIO/WHT

PNK

BRN

BLK

GRY VIO

REDBLK

YEL

BLU

BLK

RED RED

BLK

RE

D

RE

D

RE

D

VIO

GR

Y

RE

D

BLK

RE

DR

ED

BLK

BR

N

BLK

CLR

SH

IELD

SH

IELD

BAT

+B

AT -

AC

T +

AC

T -

MP

U +

MP

U -

MP

U-S

HIE

LD

WH

T/B

LU

YE

L

RED

WHT

CLR

BLK

RED

WHT

RED

RED

RED

RED

RED

ORG

ORG

ORG

YEL

GRN

BLU

BRN

BLK

GOVERNORACTUATOR

PC BOARD

STARTERSOLENOID

GAS VALVE

NOT USEDIGNITION COIL

DISTRIBUTOR

D

C B

A

BATTERY

- +

ENGINEGROUND

OIL PRESSURE SENDER

WATERTEMP SENDER

TRICKLE CHARGER

MAG PICK-UP

1 23 4

GRDN

U1

**

N

**R1A1

R2A2E1

E2

T1 T2

T3T4

GENERATORGROUNDING

STUD

CIRCUIT BREAKER

CT1

CT2

PLUG 2

PLUG 1

PLUG 3

PLUG 4

FUSE10 AMP

CONTROLLER

*

+ -

STARTER

PHASE TAP

INDICATION LAMP

IGNITION

EXTERNAL SENSE

ALTERNATOR/REGULATOR

MGL35/45 - 1 PHASE

24

MGL35/45 - 3 PHASE

25

MGL 35 MGL 45 MGL 60Item Part No. Part No. Part No. Part Description Qty

1 25620 25620 25620 Housing, Controller 12 65163 65163 65163 Strip, Main Terminal 13 25657 25657 25657 Mount, Compression 44 25655 25655 25655 Controller, LCD 15 25078 25078 25078 Switch, Toggle 16 25658 25658 25658 Face Plate 17 10081 10081 10081 Hinge, Face Plate 18 65223 65223 65223 Breaker, Circuit - 200 Amp 19 25586 25586 25586 Controller, Govenor 110 65224 65224 65224 Terminal, Remote Start 1* DC Harness, Engine Wire 1* AC Harness, Generator Wire 1

EXPLODED VIEW OF CONTROL BOXAND PARTS LIST OF CONTROL BOX

1

2

34

5

6

7

8

10 9

26

EXPLODED VIEW OF GENERATOR SET

1

2 9

10

7

8

3

6

5

4

11

8

1415

12

13

21

20

19

18

16 24

23

17

3133

32

27

2930

28

2625

23

24

21

22

27

MGL 35 MGL 45 MGL 60Item Part No. Part No. Part No. Part Description Qty

1 25517 25517 25517 Panel, Duct Cover 12 25615 25615 25615 Duct, Front 13 25736 25736 25736 Panel, Right Air 14 25719 25719 25719 Panel, Front Air 15 25737 25737 25737 Panel, Bottom Air 16 25745 25745 25745 Bracket, Lower Muffler 17 25730 25730 25730 Muffler 18 25591 25591 25591 Duct, Front Air 29 25743 25743 25743 Pipe, Exhaust 110 25747 25747 25747 Bracket, Upper Muffler 111 25742 25742 25742 Pipe, Exhaust 112 25704 25704 25704 Panel, Front 113 25567 25567 25567 Bracket, Lower Radiator 114 25735 25735 25735 Panel, Left Air 115 25677 25667 25667 Skid, Weldment 1* 15153 15153 15153 Battery 1

16 25728 25728 25728 Bracket, Mounting - Control Box 117 25624 25624 25624 Assy, Control Box 118 25503 25503 25503 Mount, Compression 419 25741 25741 25741 Pipe, Exhaust - “Y” 120 25740 25740 25740 Pipe, Exhaust 121 25568 25568 25568 Bracket, Upper Radiator 222 25498 25498 25498 Radiator 123 25712 25712 25712 Panel, Door - Right 224 25711 25711 25711 Panel, Door - Left 225 25333 25333 25333 Panel, Back Access 126 25718 25718 25718 Panel, Roof 127 25706 25706 25706 Bracket, Louver - Right 128 25675 25675 25675 Panel, Rear 129 25707 25707 25707 Panel, Louver 130 25705 25705 25705 Bracket, Louver - Left 131 25665 25665 25565 Generator 132 25379 25379 25379 Engine 133 25709 25709 25709 Fan, 21” 1* 25681 25681 25681 Mount, Engine 2* 25417 25417 25417 Mag Pickup 1* 25270 25270 25270 Governor 1* 25582 25582 25582 Gas Mixer 1* 25583 25583 25583 Air Cleaner 1* 25584 25584 25584 Air Cleaner Cover 1

* Not Shown