POWER PRODUCTS LLC DIESEL GENERATOR MMG75D • MMG100D 75 OPERATING MANUAL Parts manuals available online! www.m-p-llc.
INTRODUCTION This manual provides information and procedures to safely operate and maintain the engine and generator. For your own safety and protection from physical injury, carefully read, understand, and observe the safety instructions described in this manual. The information contained in this manual was based on machines in production at the time of publication. Magnum Power Products LLC reserves the right to change any portion of this information without notice.
TABLE OF CONTENTS Page INTRODUCTION ............................................................................................................................... 2 SAFETY NOTES ............................................................................................................................... 6 OPERATING SAFETY ...................................................................................................................... 6 ENGINE SAFETY ...................................................
FUEL TRANSFER PUMP OPTION ................................................................................................. 45 VISCOUS FAN CLUTCH OPTION .................................................................................................. 46 AC WIRING DIAGRAM - 3 POSITION VOLTAGE SELECTOR SWITCH ...................................... 47 AC WIRING DIAGRAM - 4 POSITION VOLTAGE SELECTOR SWITCH OPTION ........................ 48 AC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT ............................
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SAFETY NOTES This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. This manual contains DANGERS, WARNINGS, CAUTIONS, NOTICES and NOTES which must be followed to prevent the possibility of improper service, damage to the equipment, personal injury or death.
ENGINE SAFETY Internal combustion engines present special hazards during operation and fueling! Failure to follow the safety guidelines described below could result in severe injury or death. Read and follow all safety warnings described in the engine operator's manual. A copy of this manual was supplied with unit when it was shipped from the factory. • DO NOT run engine indoors or in an area with poor ventilation.
TOWING SAFETY Towing a trailer requires care! Both the trailer and vehicle must be in good condition and securely fastened to each other to reduce the possibility of an accident. Also, some states require that large trailers be registered and licensed. Contact your local Department of Transportation office to check on license requirements for your particular unit. • Check that the hitch and coupling on the towing vehicle are rated equal to, or greater than, the trailer's Gross Vehicle Weight Rating (GVWR).
REPORTING TRAILER SAFETY DEFECTS If you believe your trailer has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Magnum Power Products LLC. If NHTSA receives similar complaints, it may open an investigation; and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
SAFETY SYMBOL SUMMARY This equipment has been supplied with numerous safety and operating decals. These decals provide important operating instructions and warn of dangers and hazards. Replace any missing or hard-to-read decals and use care when washing or cleaning the unit. Decal placement and part numbers can be found in the parts manual. Below is a summary of the intended meanings for the symbols used on the decals. M 10 Safety alert symbol; used to alert you to potential personal injury hazards.
SPECIFICATIONS - MMG75D Read this manual carefully before attempting to use this generator. The potential for property damage, personal injury or death exists if this equipment is misused or installed 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 MMG75D Super Start Engine Make/Brand..................................
SPECIFICATIONS - MMG100D Read this manual carefully before attempting to use this generator. The potential for property damage, personal injury or death exists if this equipment is misused or installed 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 MMG100D MMG100D Super Start Engine Make/Brand...............................
UNIT DIMENSIONS Read this manual carefully before attempting to use this generator. The potential for property damage, personal injury or death exists if this equipment is misused or installed 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) ...............................
UNIT SERIAL NUMBER LOCATIONS Refer to the locations illustrated below to find the unit ID tag and VIN tag on your unit. Important information, such as the unit serial number, model number and Vehicle Identification Number (VIN) for your trailer are found on these tags. Record the information from these tags, so it is available if the tags are lost or damaged. When ordering parts or requesting technical service information, you will be asked to provide this information.
COMPONENT LOCATIONS Engine Access Central Lifting Eye Voltage Selector Switch Access Radiator Access Generator Access Engine Exhaust Handle Front Hood Latch Engine Battery Access Radiator Drain Port Fuel Fill Oil Drain Port Emergency Stop Control Panel Access 15
MAIN CONTROL PANEL FEATURES, STANDARD 2 3 4 5 1 DISABLE AUSSCHALTEN DESACTIVAR DÉSACTIVER AUTO EXHAUST FILTER CLEANING AUTOMATISCHE ABGASFILTERREINIGUNG ENABLE EINSCHALTEN ACTIVAR ACTIVER LIMPIEZA AUTOMÁTICA DE FILTRO DE ESCAPE NETTOYAGE DU FILTRE D’ÉCHAPPEMENT AUTO 12 6 7 11 8 10 16 9
1. MAIN CIRCUIT BREAKER: This breaker will disconnect power to the connection lugs (items 10-11). It WILL NOT disconnect power to the convenience outlets when the engine is running. 2. MAGNUM DIGITAL CONTROLLER (MDC): Refer to “Magnum Digital Controller (MDC)” on page 18 . 3. AUXILLIARY LIGHT SWITCHES (OPTIONAL): These switches operate the control panel and interior lights. 4.
MAGNUM DIGITAL CONTROLLER (MDC) The Magnum Digital Controller (MDC) is an enhanced digital generator controller used to start, stop and monitor the operation of the generator and the engine. The controller constantly monitors vital generator and engine functions for a number of pre-programmed alarm and fault conditions.
• • • “AUTO ” Button: Press this button to change from Manual starting mode to Automatic (remote) starting mode. “ALARM CANCEL” Button: When an alarm is activated, either visually or audibly, press this button to silence or cancel the alarm. “FAULT RESET” Button: Press this button to clear the fault from the LCD window after the fault has been corrected. Press “FAULT RESET” and “ENTER” to clear the John Deere ECU Alarm List Codes. 3.
• • • • Oil Pressure: Displays engine oil pressure. The display registers oil pressure between 0-100 psi (0-689 kPa). Normal operating pressure is between 35-80 psi (241-552 kPa). Engine Temp: Displays the temperature of the engine’s coolant. If the coolant temperature exceeds the maximum water temperature of 230°F (110°C) the engine will automatically shut down. Zero “0” will be displayed until a minimum temperature of 100°F (38°C) is reached.
• “Password” screen: The operator may press the “” or “” buttons on the “DIAGNOSTICS” keypad to move the cursor (>) up or down a list of text. • “History” screen: The operator may press the “” or “” buttons on the “DIAGNOSTICS” keypad to move the cursor (>) up or down a list of recent alarm or shutdown codes.
• “DPF Inhib” area: This area will display the “Disabled Regeneration” indicator above the words “DPF Inhib” when auto exhaust filter cleaning is disabled. • “Alarm” area: This area will display the “Yellow Alarm” or “Red Alarm” indicator above the words “Alarm” when an alarm condition occurs. The “Alarm” area displays different text depending upon which alarm condition occurs. The “Alarm” will read “Yel Alarm” if a yellow alarm condition occurs and “Red Alarm” if a red alarm condition occurs.
To adjust the output voltage, check the output voltage on the generator display screen. Look at the “L1N” voltage or the “L12” voltage on the display. The generator nominal output voltage should be within 10% of the voltage rating on the voltage selector switch. To adjust the output voltage, use a flat head screwdriver to turn the screw in the desired direction until the required voltage shown on the LCD window matches the stated voltage on the voltage selector switch.
TO CLOSE THE FRONT HOOD: 1. Make sure the skid is free of debris and all personnel are clear of unit. CAUTION Do not attempt to close the hood from the sides of the unit. Proceed to the front of the unit to close the hood. Failure to close the hood correctly could result in personal injury and equipment damage. 2. While standing at the front of the unit, slowly push the hood forward and allow it to close firmly to ensure the hood latch is engaged. 3.
MANUAL STARTING OF THE GENERATOR 1. Move the control ON/OFF toggle switch to the “CONTROL ON/I” position. DANGER CARBON MONOXIDE: USING A GENERATOR INDOORS CAN KILL YOU IN MINUTES! 2. The Liquid Crystal Display (LCD) window will quickly display information, all Light Emitting Diodes (LED’s) will flash. The information will include the company name, unit model number, part number of the programmed controller along with its revision, and the company website along with their number. 3.
6. The Running screen will display. Note: It may take a few seconds for the engine to run smoothly and reach its governed operating speed. The 45 second “V Detect” time delay will start to count down. OFF MAN AUT 7. The LCD window will then toggle from the Running screen to the Generator 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”.
“AUTO” (REMOTE) STARTING OF THE GENERATOR The “AUTO” button is used when the generator is started from a location other than the control panel and by using a 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. Refer to “Manual Starting Of The Generator” on page 25.
EXHAUST FILTER CLEANING OPERATIONS When enabled, the exhaust filter system goes through an automatic cleaning process known as regeneration. Under normal circumstances, regeneration occurs without interruption of unit operation and with minimal operator involvement. In the event there are conditions requiring the operation of the unit with auto exhaust filter cleaning disabled, the operator may be required to perform procedures to enable or disable the auto exhaust filter cleaning.
MDC CONTROLLER INFORMATION DISPLAYS, FUNCTIONS, AND RESET The Magnum Digital Controller (MDC) constantly monitors vital generator and engine functions for a number of operation, alarm and fault conditions. When a fault condition occurs, the engine will shut down automatically and the Liquid Crystal Display (LCD) window will show the fault that has caused the shutdown. To resume operation, the fault condition must be resolved. To reset the controller and resume operation, press the “FAULT RESET” button.
MAGNUM DIGITAL CONTROLLER (MDC) - LIST OF ALARMS Shutdown and warning fault conditions and the displayed message are described in the following table: No. Events Specification Information on Protection Binary Output Type Available 1 AnInIOM Sd SD YES 2 AnInIOM Wrn WRN YES 3 Battery Flat SD YES 4 Binary Input CONFIG.
No. Events Specification Information on Protection Binary Output Type Available 27 Vgen<, > SD YES 28 Vgen unbal SD NO 29 Wrn ECU Alarm WRN NO 30 Wrn RA15 fail WRN NO 31 WrnMaintenance WRN NO 32 CheckDPFStatus WRN NO Description The generator voltage is out of limits given by Gen
No. 9 10 11 12 13 14 15 16 17 18 19 SPN Description SPN:651 InjectorCyl#1 SPN:652 InjectorCyl#2 SPN:653 InjectorCyl#3 SPN:654 InjectorCyl#4 SPN:655 InjectorCyl#5 SPN:656 InjectorCyl#6 SPN:677 EngStartRelay SPN:1485 ECU MainRelay SPN:3719.15 High soot load caution SPN:3719.16 Very high soot load warning SPN:3719.00 Very high soot load - needs service *Note: The Suspect Parameter Number (SPN) is displayed as “FC” on the bottom left of the LCD window. Refer to Figure 1.
ADJUSTING THE DISPLAY BACKLIGHTING The brightness on the Liquid Crystal Display (LCD) window may be adjusted by the operator whenever the Magnum Digital Controller (MDC) is powered up. Note: Anytime an “*” is displayed on the LCD window, the text or set point cannot be changed without the use of a password. Contact Magnum Power Products LLC Technical Support for assistance. 1. Press and hold “Enter,” then press “” or “” on the diagnostics keypad to increase or decrease the brightness as needed. 2.
3. If the oil level is good, restart the unit and verify the loss of oil pressure. Shut the engine down immediately if the oil pressure value does not read five (5) psi (34 kPa) within five (5) seconds. 4. Check the oil pressure sender. To identify corrective action, refer to the troubleshooting section of the engine operation and maintenance manual provided with the unit. LOW COOLANT LEVEL SHUTDOWN 1. Allow the engine to cool. 2. Check the coolant level in the radiator.
GENERATOR OUTPUT CONNECTION LUGS The generator is equipped with connection lugs behind the lug box door located on the lower portion of the control box. The lugs provide connection points for attachment of external loads to the generator. A large decal on the inside of the connection lug door details the proper connections for selected voltages. WARNING It is HIGHLY RECOMMENDED that only a trained and licensed electrician perform any wiring and related connections to the generator.
VOLTAGE SELECTOR SWITCH The voltage selector switch is located on a panel attached to the generator behind the door located next to the fuel tank filler. The selector switch is a three position switch that mechanically changes the connections between the generator output leads and the connection lugs on the main control panel. Voltage ranges are selected by rotating the handle on the switch to the desired voltage.
4-POSITION VOLTAGE SELECTOR SWITCH OPTION The optional four position voltage selector switch is located on a panel attached to the generator behind the door located next to the fuel tank filler. The voltage selector is a four position switch that mechanically changes the connections between the generator output leads and the connection lugs on the main control panel. Voltage ranges are selected by rotating the handle on the switch to the desired voltage.
EMERGENCY STOP SWITCH E ER GEN Y M C The generator is equipped with one emergency stop switch, located on the right rear corner of the unit next to the control door. The switch is clearly labeled “EMERGENCY STOP” and is red in color. The switch can be accessed and activated with all doors closed and locked. STOP Activate the emergency stop switch by pushing the red button in until it locks down.
CUSTOMER CONVENIENCE OUTLETS The generator is equipped with five convenience outlets. The large outlets are 240/120VAC twist-lock receptacles rated at 50A each. The smaller outlets are 120VAC duplex receptacles rated at 20A each with ground fault circuit interrupt (GFCI) protection. These receptacles are not routed through the main circuit breaker. Each receptacle has its own circuit breaker, located directly above or next to the outlet.
TRANSFER SWITCH When the generator is used as a standby power supply, it must be equipped with a transfer switch which isolates it from the utility’s distribution system. A transfer switch is designed to transfer electrical loads from the normal power source (utility) to the emergency power source (generator) when normal voltage falls below a prescribed level. The transfer switch automatically returns the load back to the normal source when power is restored back to operating levels.
BELT TENSION John Deere engines use two types of belt tensioners: manual and automatic. Adjust the belt using the manual tensioner according to the manufacturer’s specifications. The automatic tensioner cannot be adjusted or repaired and is designed to maintain proper tension over the belt’s life. Units with the automatic belt tensioner must be inspected according to the manufacturer’s specifications.
• • Never wash the engine block or fuel tank with a power washer or steam cleaner. Water may enter the cabinet and collect in the generator windings or other electrical parts, causing damage. If the unit is stored outside, check for water inside the cabinet and generator before each use. If wet, dry the unit thoroughly before starting.
Item Daily 250 Hrs. 500 Hrs./12 Months Check generator drive plate torque (see page 45) Test thermostats Replace air cleaner elements Replace alternator and fan belts Check fuses Add coolant Check electrical wiring and connections * ** 3000 Hrs./ 36 Months As Required Replace primary air cleaner when dust valve restriction indicator gauge shows a vacuum of 25 in. H2O. Change the oil and oil filter after the first 100 hours, then every 250 hours.
LIFTING THE GENERATOR Central Lift Eye A large central lifting eye is located on the top of the generator. The eye is connected to a central lifting frame inside the unit. Attach a sling or hook directly to the lifting eye only if the devices are in good condition and the equipment being used to raise the unit has sufficient capacity. For approximate weights, refer to the Specifications section pages 11 - 12. Always remain aware of others around you when moving or lifting the generator.
CHECKING GENERATOR DRIVE PLATE TORQUE Follow the procedure below to check the torque of the generator drive plate bolts in accordance with the maintenance chart. Refer to “Basic Maintenance Schedule - John Deere Engine” on page 42. 1. Disconnect the engine starting battery. 2. Remove the generator fan guard. 3. Torque each of the drive plate bolts to the appropriate specification shown in the table below. Unit ft-lb (Nm) MMG75D 36 (49) MMG100D 36 (49) 4. Reinstall the generator fan guard.
VISCOUS FAN CLUTCH OPTION The viscous fan clutch option allows the engine cooling fan to engage at lower speeds, and disengage at higher speeds, increasing cooling 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.
AC WIRING DIAGRAM - 3 POSITION VOLTAGE SELECTOR SWITCH 120V GFCI RECPT MECHANICAL LUGS 11 LUG DOOR SAFETY SWITCH NO L1 L2 L3 L0 GND 120V 20A BRKER 12 120V 20A BRKER GRN/YEL GRN/YEL GRN/YEL GRN/YEL GRN/YEL 12VDC SHUNT BRN/WHT BRN/WHT GROUND TO GEN FRAME MAIN CIRCUIT BREAKER 120V GFCI RECPT BRN BRN WIRES NOT USED IN BUCK BOOST OPTION BLK BLK BLK (T7) PAIR BLK BLK PAIR BLK (T9) BLK BLK CT-1 CT-2 BLK 240V 50A BREAKER BLK 240V 50A RCPT. BLK 240V 50A RCPT.
H3 H1 BLK H2 H4 X1 BLK 3 F+ F4 AMP FUSE 7 6 ON REGULATOR 4 50HZ 60HZ BRN/WHT RED F+ BLK FWHT BLK BRN SE350 VOLTAGE REGULATOR X2 X4 NO 7 8 6 NC 4 5 X3 COM 2 3 WHT 5 BLK BLK 2 7 8 6 BLK (2.
POWER RELAY RED X2 X3 TO L0 H3 BLK H2 BUCK XFORMER H1 X4 NO 7 8 6 NC 5 4 1 COM 2 3 BLK L1 H4 X1 L2 TO LUG BLOCK L0 GND L3 GROUND ALT CAM L1 LOCK PANEL L2 L3 TO LUG BLOCK L0 GND GROUND BRN BRN TO L0 WHT 5 BLK BLK 2 7 8 6 VOLTAGE RELAY TO T7 TO 120V BREAKERS BUCK TRANSFORMER TO MAIN BREAKER L3 WHT L2 T9 T7 BR/WT 33 USED ON SOME MODELS BRN R S 21 PIN DEUTSCH CONN-2 L2 BR/WT TO T8 BR/WT BRN L1 OPTIONAL RECONNECT DOOR 34 PMG CIRCUIT BREAKER
L2 L3 N PHASE B VOLTAGE PHASE C VOLTAGE RED/BLK RED/VIO RED/VIO C2 +12VDC BO2 FUEL BO3 BO4 GRY SHIELD MANUAL INHIBIT AUTO SHIELD NOT CONNECTED CUT BACK AND TAPE BLK H L COM ECU L ECU COM PIN LOCATION 1 2 TB REMOTE START CONTACTS BLK INHIBIT REGEN SWITCH GRY/GRN GRY/BLU ECU H PLUG LOCATION LEFT SIDE 3 PIN PLUG GRY/ORG BI2 BI3 BI4 BI5 BI6 BI7 REMOTE START LOW COOLANT RECONNECT DOOR INHIBIT REGEN FORCE REGEN OPEN GRY/BLK GRY BI1 PIN LOCATION 7 PIN PLUG (BINARY INPUTS) PLUG
RD/BK 2 1 3 4 5 LIGHT ENABLE SWITCH 6 30 87A 87 85 GY/OR GY/OR X W OR 22 23 OR 31 PIN 21 20 DEUTSCH CONN-2 21 PIN TO GND BAR TO CONT BO7 TO BATT+ CONTROL POWER SWITCH 86 FAN CLUTCH RELAY H J BK BK/WT GY/OR FAN CLUTCH FAN CLUTCH INTERIOR LIGHT 2 INTERIOR LIGHT 1 CONTROL PANEL LIGHT PANEL LIGHT RD/BK MTB 31 PIN DEUTSCH CONN-2 10 11 12 21 PIN DEUTSCH CONN-2 9 RD/BK BK 8 DOOR SWITCH MTB 4 DOOR 10 11 12 PANEL LIGHT 9 FLIPHOOD LIGHT SWITCH RD/BK 7 MAIN
TO CONTROL BOX L3 L2 L1 LO L9 TO CONTROL BOX L3 L2 L1 LO 208/120V 3PH LOW WYE TO GENERATOR L9 L7 TO CONTROL BOX L3 L1 LO TO CONTROL BOX L3 L1 LO 240/120V 1 PH LOW ZIG ZAG TO GENERATOR TO GENERATOR NOTE: 1. CABLES TO CONTROL BOX MAY CONTAIN 1, 2 OR 3 WIRES DEPENDING ON THE MODEL AND VOLTAGE. 2. APPLIES TO ALL 12 LEAD GENERATORS TO BE HARD WIRED IN GEN BOX.
TRAILER WIRING DIAGRAM WT BN BN YL GN TRAILER PLUG BK AMBER MARKER LAMP WT BK RED MARKER LAMP WHITE MARKER LAMP STOP-TURN SIGNAL LAMP (LEFT) BK WT BN WT WT BK BN WT WT BN WT AMBER MARKER LAMP BK WT RD YL GN RD BK BN BN BK WT WT WT WT RED MARKER LAMP STOP-TURN SIGNAL LAMP (RIGHT) 90431_ORG_09.11.
WHT BLU SWITCH BREAKAWAY BLK WHT BATTERY BLU WHT BLU BRAKE BLU WHT BRAKE BLU WHT BRAKE BLU BRAKE BLU TRI-AXLE BLU TANDEM AXLE WHT BLU BLU WHT 90286_D_10.31.
SERVICE LOG OIL GRADE AND TYPE: ___________________________ BRAND:___________________________________ COOLANT MIXTURE: _____________________________ BRAND:___________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ ________________________________________________
REV: B PART NO: 32668 03.15.
