Magnum MMG100D, Operating Manual

Page 1: ...Parts manuals available online www m p llc com POWER PRODUCTS LLC DIESEL GENERATOR 75 MMG75D MMG100D OPERATING MANUAL ...

Page 2: ...ine operators manual are available from the engine manufacturer MAGNUM POWER PRODUCTS LLC 215 Power Drive Berlin WI 54923 U S A Phone 920 361 4442 FAX 920 361 4416 Toll Free 1 800 926 9768 www m p llc com For technical or parts QUESTIONS please contact the Magnum Power Products LLC Customer Support or Technical Support team at 1 800 926 9768 Please have your serial number available Visit www m p l...

Page 3: ...IGITAL CONTROLLER MDC GENERATOR OPERATIONAL STATUS 29 MAGNUM DIGITAL CONTROLLER MDC ALARM MANAGEMENT 29 MAGNUM DIGITAL CONTROLLER MDC LIST OF ALARMS 30 JOHN DEERE ECU INFORMATION DISPLAYS AND FUNCTIONS 31 MDC CONTROLLER HISTORY 32 ADJUSTING THE DISPLAY BACKLIGHTING 33 RESETTING THE TIME TO SERVICE REMINDER 33 TROUBLESHOOTING AUTOMATIC SHUTDOWN CONDITIONS 33 GENERATOR OUTPUT CONNECTION LUGS 35 VOLT...

Page 4: ...7 AC WIRING DIAGRAM 4 POSITION VOLTAGE SELECTOR SWITCH OPTION 48 AC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT 49 DC WIRING DIAGRAM 50 DC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT 51 WIRING BLOCK DIAGRAM DEDICATED 12 LEAD GENERATORS OPTION 52 TRAILER WIRING DIAGRAM 53 WIRING HARNESS ELECTRIC BRAKE OPTION 54 SERVICE LOG 55 ...

Page 5: ...This Page Intentionally Left Blank 5 ...

Page 6: ... 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 andcontrols Inexperiencedoperatorsshouldreceiveinstructionfromsomeone familiar withtheequipment before being allowed to operate or set up the generator The followin...

Page 7: ...n 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 ELECTRICAL SAFETY The unit is powered by a generator driven by a diesel engine While the engine is running potentially ...

Page 8: ...ecommended 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 Before towing the trailer check that the weight of the trailer is equal across all tires On trailers with adjustable height hitches adjust the angle of the trailer tongue to keep the trailer as level as possible On units equipped with a tandem axle tr...

Page 9: ... 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 Je...

Page 10: ...his area Isolate generator to prevent electrocution hazard Use clean diesel fuel only Never change switch position while engine is running Remove negative battery cable before performing any service on unit Stop engine before making connections Fire explosion hazard keep open flames away from unit Lift here only Asphyxiation hazard operate in well ventilated area Safety alert symbol used to alert ...

Page 11: ...6 70 88 Amps 3Ø Standby 480V 208V A 103 239 106 244 3Ø Prime kW kVA 62 77 63 79 Amps 3Ø Prime 480V 208V A 93 214 95 219 1Ø Standby kW kVA 60 60 66 66 Amps 1Ø Standby 240V A 250 275 1Ø Prime kW kVA 56 56 60 60 Amps 1Ø Prime 240V A 233 250 Frequency Hz 60 60 Power Factor 1 1Ø 0 8 3Ø 1 1Ø 0 8 3Ø Weights Dry Weight Skid Mounted lbs kg 3530 1600 3860 1750 Operating Weight Skid Mounted lbs kg 4700 2131 ...

Page 12: ...88 110 Amps 3Ø Standby 480V 208V A 129 297 132 305 3Ø Prime kW kVA 78 98 80 100 Amps 3Ø Prime 480V 208V A 118 272 120 278 1Ø Standby kW kVA 75 75 78 78 Amps 1Ø Standby 240V A 313 325 1Ø Prime kW kVA 71 71 72 72 Amps 1Ø Prime 240V A 296 300 Frequency Hz 60 60 Power Factor 1 1Ø 0 8 3Ø 1 1Ø 0 8 3Ø Weights Dry Weight Skid Mounted lbs kg 3763 1707 3910 1774 Operating Weight Skid Mounted lbs kg 4950 224...

Page 13: ...alled incorrectly Read all of the manuals included with this unit Each manual details specific information regarding items such as set up use and service requirements SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE MAGNUM MODEL MMG75D 100D Dimensions L x W x H Skid Mounted in m 119 x 40 x 68 3 02 x 1 02 x 1 73 Trailer Mounted in m 170 x 69 x 86 4 32 x 1 75 x 2 18 40 119 68 69 170 86 ...

Page 14: ...r Drive Berlin WI 54923 1 800 926 9768 TIRE AND LOADING INFORMATION RENSEIGNEMENTS SUR LES PNEUS ET LE CHARGEMENT SEE OWNER S MANUAL FOR ADDITIONAL INFORMATION VOIR LE MANUEL DE L USAGER POUR PLUS DE RENSEIGNEMENTS VIN Tag MANUFACTURED BY FABRIQUE PAR Magnum Power Products LLC DATE 00 0000 GVWR PNBV 000KG 0000LBS COLD INF PRESS PRESS DE V I N N I V 00000000000000000 TYPE TRAILER MODEL XXX000 GAWR ...

Page 15: ... Selector Switch Access Handle Front Hood Latch Engine Exhaust Fuel Fill Oil Drain Port Radiator Drain Port Control Panel Access Emergency Stop Central Lifting Eye Engine Battery Access Generator Access Engine Access Radiator Access ...

Page 16: ...5 6 7 9 10 11 1 8 4 3 12 AUTO EXHAUST FILTER CLEANING LIMPIEZA AUTOMÁTICA DE FILTRO DE ESCAPE AUTOMATISCHE ABGASFILTERREINIGUNG NETTOYAGE DU FILTRE D ÉCHAPPEMENT AUTO ENABLE EINSCHALTEN ACTIVAR ACTIVER DISABLE AUSSCHALTEN DESACTIVAR DÉSACTIVER ...

Page 17: ...ay require Ground Fault Circuit Interrupt GFCI protection 7 50A CIRCUIT BREAKERS 2 Circuit breakters for the 120 240V twist lock outlets 8 REMOTE START TERMINAL BLOCK Used to connect the generator to a dry contact closure switch for remote starting of the generator 9 120 240V TWIST LOCK CONVENIENCE OUTLETS 3 These outlets are used for connecting additional loads or equipment to the generator in 24...

Page 18: ...ustment Screw the OPERATION keypad the LCD window the DIAGNOSTICS keypad and the STATUS Light Emitting Diodes LED s DIGITAL CONTROLLER FEATURES AND FUNCTIONS 1 The CONTROL ON 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 ...

Page 19: ...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 and ready for the remote start signal Running Indicates the unit is running Supplying Load Indicates a load is being applied to the generator GENERATOR MONITORING Generator information is shown on the Liquid Crystal Display LCD window in a togglin...

Page 20: ... 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 In each of these page selections the operator may press the or buttons on the DIAGNOSTICS keypad to display additional information as follows Running screen The operator may press the or buttons on the DIAGNOSTICS keypad to display the...

Page 21: ...is section gives an explanation of the indicators that are displayed on the DPF Status screen on the Magnum Digital Controller Diesel exhaust filter information can be found on the Liquid Crystal Display LCD window To access the DPF Status screen press the or buttons on the DIAGNOSTICS keypad to toggle through screens until the DPF Status screen appears There are four areas on the DPF Status scree...

Page 22: ...up of the generator the Running screen of the Magnum Digital Controller MDC will display V Detect and will count down from 45 seconds to zero This is a safety feature of the controller to protect the generator from over or under voltage upon start up V Detect is a 45 second time delay and count down process before the MDC records the generator nominal output voltage This nominal generator voltage ...

Page 23: ...enerator display screen must be within 10 of the 208 120V position 188 228V line to line 108 132V line to neutral Note Each time the voltage selector switch is changed from one setting to another an adjustment will need to be made to the fine voltage using this adjustment screw FRONT HOOD OPERATION WARNING Stay clear of hood and lift structure when opening and closing generator hoods Personal inju...

Page 24: ... of this manual Make sure the control ON OFF toggle switch is in the OFF O position Make sure the circuit breakers main and convenience are switched OFF O Check that the generator is properly grounded to a good earthen ground per local and NEC regulations Check all electrical connections at the connection lugs and cam lock receptacles if equipped Are they wired correctly Are they tight Check the v...

Page 25: ... name unit model number part number of the programmed controller along with its revision and the company website along with their number 3 The LCD window will indicate MAN manual mode and Ready The Ready Manual LED will be lit Note The unit must be in the MAN mode with the Ready Manual LED lit to start the unit 4 Press the green ENGINE START button The Prestart Preheat screen will be displayed if ...

Page 26: ...the engine starts it will immediately begin speeding up to a constant 1800 rpm The engine may hunt or change speeds until operating speed is reached After a few minutes of operation the engine will be warmed up and the LCD window will show engine and generator operating parameters Temperature will be shown as 0 until the engine temperature is approximately 100 F 38 C 11 Check the generator for exc...

Page 27: ...ontacts The engine should crank start and run 3 Remove the jumper wire from the remote start terminal block and the engine will stop Reconnect any necessary wires from the remote start switch transfer switch to the remote start terminal block 4 Confirm unit is in AUTO mode The LCD window should have AUT highlighted in the upper left corner 5 Close the main circuit breaker set to ON I 6 Secure the ...

Page 28: ...osition 3 Toggle to the DPF Status screen on the Magnum Digital Controller and verify the Disabled Regener ation indicator appears above the words DPF Inhib For information regarding the DPF Status screen and indicators refer to Diesel Exhaust Filter Monitoring on page 21 Note Disabling auto mode is not recommended for any situation unless it is safety related or if the fuel tank lacks the require...

Page 29: ...on 1 AfterCool Engine aftercooling Cooling Pump output is closed 2 Cooling The unit is cooling before stop 3 Cranking Engine is cranking 4 EmergMan Emergency Manual gen set operation 5 Init Autotest during controller power on 6 Not Ready The unit is not ready to start 7 Pause Pause between start attempts 8 Prestart Prestart sequence in process Prestart output is closed 9 Ready The unit is ready to...

Page 30: ...n Wrn Fuel Level setpoint 12 GCB fail SD NO Failure of 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 smaller than Sd Oil Press setpoint 16 Oil Press Wrn WRN YES Oil pressure is smaller than Wrn Oil Press setpoint 17 Overload SD YES The load is greater than the value give...

Page 31: ...nce Counter OC are shown together with a description if possible One SPN FMI describes one failure If FMI is equal to zero or one WRN is displayed in the ECU Alarm list For any other FMI value FLS is displayed Detailed SPN FMI information may be found in the SAE HS 1939 Publication or refer to engine manufacturers ECU error codes list The following table shows the ECU messages displayed with their...

Page 32: ...3 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 a...

Page 33: ...e current service time hour setting remaining 0 will be one line below it on the right side 5 Press Enter The current run time in hours will now appear on the left side of the display screen directly under WrnMaintenance 6 Press the button and reset the current run time hour setting to 250 If you pass the 250 time interval use the button to get back to the 250 time interval 7 Press Enter to save t...

Page 34: ...w and then check the level of coolant in theradiator Toaccess the radiatorcap you mustremove the access panel from thetop of the enclosure directly above the radiator Add coolant until it is 3 4 in 2 cm below the filler neck Secure the radiator cap back into its original position 4 Check the radiator shroud and ducting for blockage and remove any foreign matter 5 Inspect coolant hoses engine block...

Page 35: ...CALSYSTEM CAN CAUSE POTENTIALLY LETHAL VOLTAGES TO BACKFEED ONTO UTILITY LINES THIS MAY RESULT IN INJURY OR ELECTROCUTION TO UTILITY WORKERS NEARBY MAKE SURE THE GENERATOR IS SUPPLYING POWER TO AN ISOLATED OBJECT OR BUILDING THAT IS NOT CONNECTED TO ANY UTILITY LINES Connections to the lugs should be made by running the power cables up through the slot in the bottom of the box Use a hex wrench to ...

Page 36: ...zed personnel from changing the switch settings Note UNITS WITHOUT A CONVENIENCE OUTLET BUCK TRANSFORMER 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 lock outlet...

Page 37: ...n place you will prevent unauthorized personnel from changing the switch settings Note UNITS WITHOUT A CONVENIENCE OUTLET BUCK TRANSFORMER When the voltage selector switch is in position for 277 480V 3Ø voltage at the two GFCI duplex convenience outlets is 139 volts and the voltage at the three twist lock outlets is 139 240 volts When the voltage selector switch is in position for 120 208V 3Ø volt...

Page 38: ...d with this unit to apply additional leverage to the switch The main circuit breaker will be tripped disconnecting power to the connection lugs if any of the following items occur while the unit is running 1 Overload of the generator circuits to the connection lugs 208 120V only 2 The door covering the customer connection lugs is opened 3 If the emergency stop switch is activated Make sure that an...

Page 39: ...utlets is 139 volts and the voltage at the three twist lock outlets is 240 139 volts When the shorting board is in position for 208 120V 3Ø voltage at the three twist lock outlets and the two GFCI outlets is 208 120 volts DERATING FOR ALTITUDE All generator sets are subject to derating for altitude and temperature this will reduce the available power for operating of tools and accessories connecte...

Page 40: ...irections supplied by the manufacturer of the switch If attaching generator to a power supply normally serviced by a utility company notify the utility company and check local and state regulations Familiarize yourself with all instructions and warning labels supplied with the switch WARNING It is strongly recommended that ONLY a licensed electrician perform any wiring or any related connections t...

Page 41: ... in the crosshatch pattern between the FULL and ADD markings Add oil to the engine only if the level is below the ADD mark on the bottom of the crosshatch pattern DO NOT OVERFILL the crankcase Consult the engine operation and maintenance manual for the proper grade of oil including special operating conditions such as a change in season or climate Check the coolant level daily The coolant is check...

Page 42: ...mover BASIC MAINTENANCE SCHEDULE JOHN DEERE ENGINE Refer to the original equipment manufacturer s operating manual for a complete list of maintenance requirements Failure to comply with the procedures as described in the engine operator manual will nullify the warranty decrease performance and cause equipment damage or premature equipment failure Use the schedule in the following table as a guide ...

Page 43: ...stem contains a diesel particulate filter DPF Over time the DPF will require professional servicing to remove ash buildup The expected service interval will be at least 3000 or 4500 hours based on engine power and operating conditions Actual service should take place when the indicator light appears on the control panel LCD The DPF should be cleaned or replaced by an authorized service provider on...

Page 44: ...rvice or replaced tighten the lugs in the order shown to the following specifications A Start all lug nuts by hand B First pass tighten to 20 25 ft lbs 27 33 Nm C Second pass tighten to 50 60 ft lbs 67 81 Nm D Third pass tighten to 90 120 ft lbs 122 162 Nm After the first road use re torque the lug nuts in sequence 6 Maximum recommended speed for highway towing is 45 mph 72 km h Recommended off ro...

Page 45: ... tank s fuel lines to the AUXILIARY FUEL INLET and AUXILIARY FUEL OUTLET fittings on the unit 3 Open the AUXILIARY FUEL INLET and AUXILIARY FUEL OUTLET valves located inside of the right front door FUEL TRANSFER PUMP OPTION The fuel transfer pump option allows the fuel tank to be refilled from an external bulk fuel source When the fuel transfer switch is on anytime the fuel level drops below 15 th...

Page 46: ...ooling system efficiency The cooling fan will engage at full speed when the coolant temperature rises When the fan is operating at full speed it will switch to a slower speed when the coolant temperature drops There will be an audible difference when the engine cooling fan switches speeds Depending on unit model the temperature ranges vary 170 200ºF 77 93ºC ...

Page 47: ... 7 BRN WHT BLK BLK F BRN MECHANICAL LUGS GROUND TO FRAME BLK BLK 50A 240V RCPT BLK GFCI RECPT 120V 17 21 25 18 22 26 19 20 23 24 27 28 T9 RCPT 240V 50A 50A RCPT 240V BLK BLK BLK T6 T8 T10 T11 T7 T1 T12 T2 T3 GENERATOR F F 120V 20A BRKER 120V RECPT GFCI L3 L2 L1 L0 SE350 VOLTAGE REGULATOR 12VDC T9 GRN YEL BRKER 20A 120V GND BLK RED LUG DOOR NO 12 11 SAFETY SWITCH LT BLU LT BLU LT BLU LT BLU LT BLU ...

Page 48: ...IRCUIT BREAKER BLK BLK BLK BLK BLK BLK BLU BLU BLU BLU 20 AMP G F I OUTLET 20 AMP G F I OUTLET 20 AMP 20 AMP 60HZ 50HZ ON REGULATOR 4 AMP FUSE WHT RED F F F 6 7 BRN WHT BLK BLK F BRN SE350 VOLTAGE REGULATOR 3 POWER RELAY BLK BLK WHT WHT WHT BLK BUCK TRANSFORMER OPTION BLK 7 8 6 5 1 2 3 4 COM NO NC BLK BLK BLK BLK BLK BLK BLK RED BLK T4 GROUND TO FRAME T9 T6 T8 T10 T11 T7 T1 T2 T3 GENERATOR F F 34 ...

Page 49: ...2 BRN BRN BR WT OFF P N DEUTSCH 21 PIN CONN 1 CONN 2 31 PIN DEUTSCH 3 2 OR F F CONN 2 21 PIN DEUTSCH M 15 DEUTSCH 31 PIN CONN 2 OR TO T8 LUG DOOR RECONNECT DOOR PMG S R BRN BRN BR WT DEUTSCH 21 PIN CONN 2 BR WT BR WT USED ON BR WT CONN 2 31 PIN DEUTSCH 6 7 OR GN YL WT RECONNECT DOOR PMG S R BRN BR WT DEUTSCH 21 PIN CONN 2 BR WT OPTIONAL CONN 2 31 PIN DEUTSCH 6 7 OR T7 T9 L1 L3 L2 BREAKER CIRCUIT G...

Page 50: ...SHUNT WHT MAIN BREAKER L0 LOWER LOWER UPPER UPPER LOWER LEFT SIDE RED WHT RED WHT 10 1 2 3 4 5 6 7 8 9 X T C A W M N P R S H J K L U E B V D F G GRY SHLD BLK GEN F RED GEN F RED WHT ORN GRN YEL GRY E STOP SWITCH NO NO 13 14 13 14 BLK RED RED F BLK RED RED SHLD GRY BLK RED VIO GRY BLK BLK GRY GRN YEL ORN RED WHT ORN ORN BLK OPEN POWER DC BO7 OPEN RED YEL RED WHT 12 11 BI7 OPEN RED BLK COMMON COM LU...

Page 51: ...ELAY RD OR 8 MTB RD WT 21 PIN P N CONN 2 DEUTSCH 1 3K OHM 300 OHM 4 PIN PLUG RD YL WT RD BK BK BK BK WT 6 WT 4 WT 12 WT 8 WT GY OR 21 PIN T CONN 2 DEUTSCH RD VI RD SPLICE RD 31 PIN DEUTSCH CONN 1 MAY VARY 1 2 3 4 5 6 7 8 9 10 11 12 MAIN POWER SWITCH LIGHT ENABLE SWITCH DOOR SWITCH PANEL LIGHT PANEL LIGHT FLIPHOOD 4 DOOR CONTROL LIGHT MTB LIGHT SWITCH 11 12 9 10 1 2 3 4 5 6 7 8 INTERIOR CABINET LIG...

Page 52: ...ZIG ZAG 480 240V 1 PH HIGH ZIG ZAG TO GENERATOR TO GENERATOR TO GENERATOR TO GENERATOR L9 L7 T10 T11 T12 T3 T9 T6 T8 T5 T2 T1 T7 T4 T1 T7 T8 T12 T3 T9 T11 T10 T5 T4 T9 T6 T5 T8 T11 T2 T10 T12 T7 T4 T1 T3 T10 T3 T9 T6 T1 T4 T7 T12 T5 T8 T2 T6 T2 T11 T9 T5 T3 T8 T4 T2 T10 T6 T7 T1 T12 T2 T8 T11 T12 T10 T6 T5 T4 T3 T9 T1 T7 L9 L7 L9 L7 L9 L7 L9 L7 T11 TO GENERATOR NOTE 1 CABLES TO CONTROL BOX MAY CON...

Page 53: ...R WT WT WT WT AMBER MARKER LAMP BK BK WT WT RED MARKER LAMP BK BK BK BK LAMP MARKER WHITE WT WT BK BK LAMP MARKER RED WT WT STOP TURN SIGNAL LAMP RIGHT LEFT SIGNAL LAMP STOP TURN WT WT BK BK RD RD WT WT RD RD BK BK WT WT GN GN BN BN WT WT BN BN BN BN WT WT BN BN WT WT YL YL BN BN WT WT 90431_ORG_09 11 12 ...

Page 54: ...KE OPTION 90286_D_10 31 12 BATTERY BREAKAWAY SWITCH BLU WHT BLK WHT WHT WHT WHT BRAKE BLU BLU BRAKE WHT BLU BLU BLU BLU WHT BRAKE BLU BLU BRAKE WHT WHT WHT TANDEM AXLE WHT BLU BRAKE WHT BLU BLU WHT BRAKE BLU WHT TRI AXLE SINGLE AXLE ...

Page 55: ...______________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ _____________________...

Page 56: ...REV B PART NO 32668 03 15 13 ...