Magnum MLT4000S Generator Set

Tools: Allen wrench, Feeler gauge, Crows foot

1. Ensure the engine is at room temperature and the piston is at Top Dead Center of its compression stroke with both valves closed.
2. Loosen the rocker arm jam nut.
3. Use an allen wrench to turn the pivot ball stub while checking clearance between the rocker arm and valve stem with a feeler gauge.
4. When clearance is correct, hold the pivot ball stud with the allen wrench and tighten the rocker arm jam nut with a crows foot to 65-85 in-lbs (7-10 Nm).
5. Recheck valve clearance after tightening the jam nut.

⚠ Do not blast the spark plug to clean.

Tools: Wire brush, Wire feeler gauge

1. Clean the area around the base of the spark plug to keep dirt and debris out of the engine; remove the spark plug and check condition.
2. Clean the spark plug by scraping or washing using a wire brush and commercial solvent; do not blast to clean.
3. Check the spark plug gap using a wire feeler gauge.
4. Adjust the gap to 0.030 inch (0.76 mm) by carefully bending the ground electrode.

⚠ The tower extends up to 25 ft (7.6 m). Make sure area above the trailer is open and clear of overhead wires and obstructions.

1. For maximum light coverage locate the tower at ground level or in a spot higher than the area being illuminated.
2. Position the unit on a firm, non-combustible surface that is relatively flat, free of overhead obstructions and has a clear southerly view.
3. Orient the unit with the trailer hitch facing north and block the wheels to keep it from moving.
4. Pull the locking pin on the tongue jack, rotate it 90°, and turn the jack handle clockwise to raise the trailer tongue off the towing vehicle.
5. If necessary, connect a good earthen ground to the grounding stud on the frame near the trailer tongue.
6. Pull the locking pin on the outriggers and extend them until the pin snaps back in place; extend the outrigger jacks to the ground.
7. Pull the locking pin on the rear jack, rotate it 90°, and turn the jack handle clockwise to level the trailer; adjust all four jacks to the ground.

⚠ DO NOT OVERFILL the crankcase.

1. Remove the three sets of hardware securing the engine cover to the engine.
2. Remove the brass oil drain set screw located on the bottom of the engine compartment and drain the oil into an approved container.
3. Remove the oil filter, located on the front side of the engine compartment.
4. Apply a light amount of new oil to the rubber gasket of the new oil filter.
5. Tighten the oil filter until the rubber gasket makes contact with the engine, then tighten 3/4 to 1 full turn more.
6. Remove the oil fill cap and slowly add oil.
7. Replace the engine cover and tighten the three sets of hardware removed in step 1.
8. Run the engine approximately five minutes, turn it off, allow the oil to settle, and check the dipstick.

⚠ Never operate the engine with the oil level below the bottom of the crosshatch area on the end of the dipstick. Major engine damage could occur.

Tools: Clean, lint-free cloth

1. Ensure the unit is as level as possible.
2. Remove the dipstick and wipe it dry with a clean, lint-free cloth.
3. Install and tighten the dipstick cap; then remove it again.
4. The oil level should be at the dipstick Full mark - the top of the crosshatch pattern.
5. If necessary, remove the oil fill cap and slowly add oil until it reaches the Full mark; DO NOT fill above the Full mark.
6. Install and tighten the oil fill cap and the dipstick before operating the engine.

1. Clean all foreign material from the air intake at least once every 100 hours of operation; clean more often if necessary.
2. Inspect the area around the generator exhaust muffler periodically and remove all grass, leaves, dirt, etc.

⚠ Wait 30 seconds after disconnecting solar panels before continuing service. Residual electrical charge may still be present.

⚠ Solar panel electrical connections can carry an electrical charge during daylight. Do not disconnect the solar panels from the chassis if exposed to direct sunlight.

⚠ Do not remove the battery covers near an open flame or other ignition source.

1. With all four jacks properly deployed, level the unit.
2. Properly configure the solar panels in the stowed position.
3. Set the timer control module to Off and the Gen Power switch to Off.
4. Remove the two solar panel electrical connections from the plugs on the rear side of the chassis.
5. Raise the solar panel tilt frame to 45° using the Panel Angle switch.
6. Remove the service pin from the 45° Operation position on the actuator lockout bracket.
7. Raise the tilt frame to the 90° position by hand and insert the service pin in the 90° Service Only position.
8. Remove the six screws securing both battery bank covers and remove the covers.
9. Disconnect the negative (-) battery cable from the corresponding terminal on BOTH rear batteries.

Tools: Grease gun, Needle nose applicator

1. Apply a small amount of automotive grease to the internal gearing by removing the jack cover, or use a needle nose applicator or grease gun on the lubrication point.
2. Rotate the jack handle to distribute the grease evenly.
3. Apply a lightweight oil to the handle unit at both sides of the tube.
4. If equipped, lubricate the caster wheel axle bolt and nut assembly with the same lightweight oil.

⚠ Always wear heavy leather gloves and eye protection when replacing LP fuel tanks. A small amount of LP vapor or liquid may escape.

1. Close the cylinder valves on BOTH LP fuel tanks and remove the supply line fitting from the tank(s) to be replaced.
2. Release the latch on the fuel tank strap and remove the strap.
3. Replace the LP fuel tank(s), positioning the cylinder valve to the right of center, in the 3 o'clock position.
4. Secure the fuel tank in place with the strap and engage the latch.
5. Secure the supply lines to the new tank(s).

Tools: Standard grease gun, Clean cloth

1. Remove the small rubber plug on the grease cap.
2. Attach a standard grease gun fitting to the grease zerk fitting and pump grease until new grease is visible around the nozzle.
3. Wipe any excess grease from the hub with a clean cloth.
4. Replace the rubber plug when finished.

⚠ Always support the solar panels down to their resting position completely. Allowing the solar panels to drop or fall may damage the solar panels and/or tilt frame.

1. Set up the unit as described in Light Tower Set Up.
2. Release the two hook clamps securing the solar panels together on both sides of the unit.
3. Rotate the top/front solar panel forward to the tilt frame and secure it using the twist lock clamps.
4. Rotate the bottom/rear solar panel backward to the horizontal position until the rubber bumpers contact the center panel.
5. Use the solar alignment guide or setup decal to calculate the optimal panel angle.
6. Raise the solar panels using the Panel Angle switch until the desired angle is reached; use the Angle Indicator to determine the angle.

⚠ Always remain aware of the position of other people and objects around you as you move the unit.

⚠ Variable fuel levels can shift the center of gravity. Always raise the unit slowly to determine the balance.

1. Make sure the lifting equipment has sufficient capacity.
2. Lower the mast to the lowest position and secure it in the stowed position.
3. Configure the solar panels in the stowed position.
4. Retract the side outriggers to their stowed position.
5. For a hoist, attach slings, chains or hooks directly to the central lift point between the solar panels.
6. For a forklift, always use the forklift pockets and approach the unit as perpendicular as possible.