POWER PRODUCTS LLC DIESEL GENERATOR MMG75D • MMG100D With TM Controller 75 OPERATING MANUAL Parts manuals available online! www.m-p-llc.
INTRODUCTION This manual provides information and procedures to safely operate and maintain the Magnum Power Products LLC unit. For your own safety and protection from physical injury, carefully read, understand, and observe the safety instructions described in this manual. Keep a copy of this manual with the unit at all times. Additional copies are available from Magnum Power Products LLC, or can be found at www.m-p-llc.com.
TABLE OF CONTENTS Page INTRODUCTION ................................................................................................................................ 2 SAFETY NOTES ................................................................................................................................ 5 OPERATING SAFETY ....................................................................................................................... 5 ENGINE SAFETY.................................................
AC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT ................................................................ 45 DC WIRING DIAGRAM .................................................................................................................... 46 DC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT................................................................ 47 WIRING BLOCK DIAGRAM - DEDICATED 12 LEAD GENERATORS OPTION ............................. 48 TRAILER WIRING DIAGRAM ........................................
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).
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 8 Safety alert symbol; used to alert you to potential personal injury hazards.
UNIT SERIAL NUMBER LOCATIONS Refer to the illustration to locate the unit ID tag and Vehicle Identification Number (VIN) tag on the unit. Important information, such as the unit serial number, model number, VIN and tire loading information 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 assistance, you may be asked to provide this information.
SPECIFICATIONS - MMG75D MAGNUM MODEL MMG75D MMG75D Super Start Engine Make/Brand...................................................................... John Deere ...................................John Deere Model ............................................................................... PE4045HFG92..............................PE4045HFG92 Horsepower - prime hp (kW) .......................................... 97 (72)...........................................97 (72) Horsepower - standby hp (kW) .....
SPECIFICATIONS - MMG100D MAGNUM MODEL MMG100D MMG100D Super Start Engine Make/Brand...................................................................... John Deere ...................................John Deere Model ............................................................................... PE4045HFG92..............................PE4045HFG92 Horsepower - prime hp (kW) .......................................... 121 (90).........................................121 (90) Horsepower - standby hp (kW) ..
UNIT DIMENSIONS MAGNUM MODEL MMG75D/100D Dimensions (L x W x H) Skid Mounted in (m) ...................................................................................................... 119 x 40 x 62 (3.02 x 1.02 x 1.57) Trailer Mounted in (m) .................................................................................................. 170 x 69 x 80 (4.32 x 1.75 x 2.03) H W L H W Specifications are subject to change without notice.
COMPONENT LOCATIONS Engine Access Central Lift Point Voltage Selector Switch Access Radiator Access Generator Access Manual Holder Access Engine Exhaust Handle Front Hood Latch Engine Battery Access Radiator Drain Port Fuel Fill Oil Drain Port Emergency Stop Control Panel Access 13
MAIN CONTROL PANEL FEATURES, STANDARD 1 12 2 11 10 3 9 4 5 8 7 14 6
1. POWER ZONE™ CONTROLLER: Refer to page 16 for additional information. 2. 50A CIRCUIT BREAKERS (3): Circuit breakters for the 120/240V twist-lock receptacles. 3. 120V GFCI DUPLEX RECEPTACLES (2): Receptacles for additional equipment that may require Ground Fault Circuit Interrupt (GFCI) protection. 4. 20A CIRCUIT BREAKERS (2): Circuit breakters for the 120V GFCI receptacles. 5. REMOTE START TERMINAL BLOCK: Used to connect the generator to a dry-contact closure switch for remote starting of the generator.
POWER ZONE™ CONTROLLER The Power Zone™ controller is an auto start controller that monitors the unit and indicates operational status and fault conditions. The controller can be programmed to automatically start or stop on based time schedule, fault condition, or load demand. The controller constantly monitors vital generator and engine functions for a number of preprogrammed alarm and fault conditions.
CONTROL POWER SWITCH Use this switch to start up and shut down the Power Zone™ controller. This switch should not be turned off when the unit is running. ENGINE START Pressing the Engine Start “I” button while the controller is in “Manual Mode” will start the unit, provided there are no shutdown errors, and the engine satisfies the start status. If the controller is in “Auto Mode”, the engine start button has no effect.
alarm status with the time remaining (black text) or the time past (red text) a scheduled maintenance tasks. GENERATOR SCREEN The Generator screen displays the average voltage frequency, volts and amps from the generator, as well as lineto-line voltage, and individual line-to-neutral voltage, amperage and power (kW). This screen also displays the generator winding configuration set by the voltage selector switch in the lower right corner.
The information displayed on the Maintenance screens can be used to identify, diagnose and troubleshoot unit shutdown conditions and poor unit performance. The Maintenance screens can be accessed from any Operator screen by pressing any directional arrow (”▲”, ”►”, ”▼”, “◄”). GENERATOR SUMMARY The Generator Summary can be found at the top of all Maintenance screens and provides an overview of the system.
ALARMS TAB The “Alarms” tab display any warnings, electrical trip and shutdown alarms and any engine Diagnostic Trouble Codes (DTC) that are occurring or have occurred previously. The first page on the “Alarms” tab displays the alarms that are currently active. They are organized by alarm type.
INPUT/OUTPUT TAB The Input/Output (“I/O”) tab shows a list of digital inputs and outputs connected to the controller, whether they are active and the current state of the input. SCHEDULE TAB The “Schedule” tab shows the current configuration and status of the scheduler, as well as maintenance configuration status and time remaining until an alarm, electrical trip or shutdown will occur. STATUS TAB The “Status” tab contains the status and configuration of the controller, firmware and data connections.
GENERATOR SCREEN The Generator screen displays the average voltage frequency, volts and amps from the generator, as well as lineto-line voltage, and individual line-to-neutral voltage, amperage and power (kW). This screen also displays the current voltage selector switch current setting. Note: When loading the generator, it is important to observe the amperage to determine the load balance on each line of the generator.
maintenance in red text. A description of the maintenance procedure and the action that will take place when the timer trips the alarm. Note: If the measured value is outside the range of a gauge, the needle will not be displayed. The digital value below the gauge will still show the measured value. • • • Oil Press: Displays engine oil pressure. Current coolant temperature is displayed directly below the gauge at all times. The gauge registers oil pressure between 0-100 psi (10-689 kPa).
• DPF Inhib: This area will display the Disabled Regeneration indicator above the words “DPF Inhib - Solid” when auto exhaust filter cleaning is disabled. • Alarm: This area will display the Engine Alarm indicator above the words “Alarm - Solid” when an alarm condition occurs. This area displays different text depending upon which alarm condition occurs.
1. With the unit running, press the “Voltage Adjust” screen button. 2. Press the Enter “” button. The voltages displayed will begin flashing. 3. Use the up and down directional arrows “▲”, “▼” to adjust the voltage. 4. Press the Enter “” button to confirm the new voltage. The voltages displayed will stop flashing. PRESTART CHECKLIST Before starting the generator, carefully read the prestart checklist. Make sure that all of the items are checked before trying to start the generator.
DANGER CARBON MONOXIDE: USING A GENERATOR INDOORS CAN KILL YOU IN MINUTES. 2. The main display will show the prestart diagnosis and the controller will load the unit management software. 3. When the software is loaded, the Home screen will be displayed and the controller will be in “Manual Mode” as indicated at the top of the screen. Note: The controller can be started from any screen when it is in “Manual Mode.” 4. Press the green Engine Start “I” button on the controller.
7. Once 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 Operator screens will show engine and generator operating parameters. 8. Check the generator for excessive noise or vibration and any coolant, oil, or fuel leaks before applying any loads. 9. Check that the AC output voltage is correct.
2. Access the “Scheduler Options” section. Within this section, the scheduler can be enabled, run mode selected, and load mode selected. Item Values Enable Yes/No Run Mode Monthly/Weekly Load Idle, In Island, On Load, Off Load 3. Access the “Scheduler Setup” section. Within this section, each schedule entry can be modified by pressing the Enter “” button to select the item and the up “▲” and down “▼” arrows to define them.
SHUTTING DOWN THE GENERATOR Check with personnel using power supplied by the generator and let them know that the power is going to be turned off. Make sure the power shut down will not create any hazards by accidentally turning off equipment that needs to be kept on (pumps, compressors, lights, etc.). 1. Remove all loads from the generator by opening all circuit breakers (turn to “OFF/O”). 2. Let the engine run for approximately five minutes to allow it to cool down. 3.
FORCE A MANUAL EXHAUST FILTER CLEANING If running the unit with the exhaust filter cleaning function disabled, the “DPF Status” screen may display a red alarm, prompting the operator to force a manual exhaust filter cleaning. Use the following procedure to force a manual exhaust filter cleaning feature: 1. Open the control door and locate the switch labeled “Auto Exhaust Filter Cleaning.” 2. Move and hold the rocker switch into the “ON / FORCED (I)” position for five seconds. 3.
8. Press the Enter “” button to reset the selected maintenance alarm. Note: If the selected maintenance alarm does not need to be reset, press the “” button to highlight “Not Reset” and press the Enter “” button return to the parameters section. 1. To perform additional maintenance alarm resets, repeat steps 6-8. 2. To save changes, press and hold the Enter “” button for five seconds. To discard changes made, press and hold the Engine Stop/Reset “O” button for five seconds.
OVERCRANK SHUTDOWN 1. Check the fuel level in the tank. 2. Check for proper operation of the fuel pump. 3. Check the air filter for blockage. 4. If the engine will not start, consult the engine operator’s manual for additional information on troubleshooting starting problems. OVERSPEED OR UNDERSPEED SHUTDOWN 1. Disconnect all loads and restart the generator. Read the frequency (Hz) on the LCD display. With no loads on the generator, the frequency should read 60.0 Hz. 2.
RUN CABLES THROUGH SLOTS 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.
The voltage selector switch is equipped with a locking mechanism. Once the proper voltage has been selected, push the red latch on the inside of the switch handle up and insert a padlock through the handle. By locking the handle in place, you will prevent unauthorized personnel from changing the switch settings.
Note: UNITS WITHOUT A RECEPTACLE BUCK TRANSFORMER: When the voltage selector switch is in position for 277/480V 3Ø, voltage at the two GFCI duplex receptacles is 139 volts and the voltage at the three twist-lock receptacles is 139/240 volts. When the voltage selector switch is in position for 120/208V 3Ø, voltage at the two GFCI duplex receptacles is 120 volts and the voltage at the three twist-lock receptacles is 120/208 volts.
VOLTAGE REGULATION The electronic voltage regulator controls the output of the generator by regulating the current into the exciter field. The regulator has six screwdriver adjustable potentiometers that may be adjusted for U/F dip, under frequency protection (U/F), droop, stabilty, voltage, and trim. The voltage regulator on your unit is adjusted before shipment from the factory. Contact Magnum Power Products LLC for additional information before attempting to adjust the voltage regulator.
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. ENGINE AND GENERATOR MAINTENANCE Check the engine oil level daily before starting the engine.
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. Maintenance records may be required to complete a warranty request. Use the schedule in the following table as a guide for regular maintenance intervals.
ash must be done by removing the DPF from the unit and placing it into specialized equipment. CAUTION Do not remove ash by using water or other chemicals. Removing ash by these methods may cause equipment damage and create unsafe operating conditions. CAUTION Only a qualified service provider should remove, handle and dispose of diesel particulate filters and ash. These materials may be considered hazardous under federal, state and local regulations, and must be handled and disposed of properly.
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-road towing speed is not to exceed 10 mph (16 km/h) or less, depending on terrain. 1 4 1 3 3 2 6 5 5 2 4 6-Stud Sequence 5-Stud Sequence TRAILER WHEEL BEARINGS The trailer axles are equipped with a grease zerk fitting to allow lubrication of the wheel bearings without the need to disassemble the axle hub.
AUXILIARY FUEL TANK OPTION The auxiliary fuel tank option is designed so the unit can run from an external fuel tank. The unit is still programmed to shut down when the internal tank’s fuel level drops below five percent. In order for the unit to run off of an auxiliary tank, the fuel level in the internal tank must remain over five percent. To operate the unit using an auxiliary fuel tank, use the following procedure: 1. Shut down the unit and check that the level of fuel in the tank is above five percent.
AC WIRING DIAGRAM - 3 POSITION VOLTAGE SELECTOR SWITCH L2 L3 L0 120V GFCI RECPT 120V GFCI RECPT MECHANICAL LUGS L1 GND 120V 20A BRKER 120V 20A BRKER GROUND TO GEN FRAME GRN/YEL GRN/YEL GRN/YEL 12VDC SHUNT MAIN CIRCUIT BREAKER GRN/YEL GRN/YEL BRN BRN WIRES NOT USED IN BUCK BOOST OPTION BLK BLK 240V 50A BREAKER BLK 240V 50A BREAKER BLK 240V 50A BREAKER BLK 240V 50A RCPT.
P2 P1 E1 E2 E3 F+ FA2 5 AMP FUSE A1 ON REGULATOR VR1 VR2 50HZ 60HZ RD BK WT BK BN BN/WT PM500 VOLTAGE REGULATOR TO POWER ZONE PIN 39 TO POWER ZONE AVR PINS BN/WT BN 29 2 3 RED BLK RD/BK CT-1 TP1 TP2 (L0) (T9) BLK BLK (T7) BLK 8 4 TP0 7 6 2 3 5 1 GROUND TO GEN FRAME 12 11 10 9 16 15 14 13 20 19 18 17 24 23 22 21 TO POWER ZONE PIN 40 BLK BLK BLK BLK BLK BLK BRN BRN GRN/YEL 10GA GRN/YEL 10GA GRN/YEL 10GA GRN/YEL 14GA GRN/YEL 14GA 28 27 26 25 TP3A 32 31
33 TO L0 H1 X2 X3 X1 USED ON SOME NON-POWER ZONE MODELS BN BLK H2 H4 L3 TO LUG BLOCK L0 GND GROUND OR M 21 PIN DEUTSCH CONN-2 OR V OR BLK 8 15 6 6 7 31 PIN DEUTSCH CONN-2 31 PIN DEUTSCH CONN-2 B USED ON MMG235 AND HIGHER 21 PIN DEUTSCH CONN-1 TO L0 5 BLK 2 7 VOLTAGE RELAY WHT TO T9 TO T7 BR/WT BN YEL BLK RED T9 T7 RECONNECT DOOR USED ON SOME NON-POWER ZONE MODELS 34 33 E1 E2 E3 40 3 4 F+ F- 39 HEATER GEN RD BK WT BK RD WT BN/WT BN N P OR OR 6
ALT RD RD STARTER 12 V BATTERY + IGNITION 30A G C W B A D T 21 PIN CONN1 RD RD E J R P S BK M L K N ENGINE GND OR U V CAN-LOW CAN-HIGH F RD/VI RD RD BK TO GND BAR OR BK CLR SHLD RD/VI RD/VI RD/VI RD RD BK/WT RD/VI RD RD RD TO GND BAR RD/BK TB1 1 20A 2 15A 3 20A 4 SPARE FUSE BLOCK RD/BK RD/VI RD/WT RD/WT RD/WT RD/WT RD/BK RD/BK RD/BK CONTROL POWER SWITCH RD/VI RD/VI CLUTCH FAN RD/WT 85 86 87 1 2 85 86 87 86 85 87 TO GND BK/WT BAR 30 R
RD/VI 30 87A 85 X W OR 22 23 31 PIN DEUTSCH CONN-2 OR 31 PIN 21 20 DEUTSCH CONN-2 H J 21 PIN TO GND BAR TO GY/OR CONT BO7 MTB PIN 1 (FUEL) OR ESTOP ON UNITS UP TO MMG55 86 87 GY/OR RD/BK BK 21 PIN DEUTSCH CONN-2 DOOR SWITCH LIGHT SWITCH RD/BK INTERIOR CABINET LIGHT FAN CLUTCH RELAY 7 FAN CLUTCH INTERIOR LIGHT 1 FAN CLUTCH BK/WT GY/OR INTERIOR LIGHT 2 PANEL LIGHT RD/BK BK 4 DOOR FLIPHOOD PANEL LIGHT MTB 10 OR 12 POS FUSED POWER LIGHT ENABLE SWITCH MAIN POWER SWI
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 BLU TANDEM AXLE WHT BLU WHT 90286_D_10.31.
SERVICE LOG OIL GRADE AND TYPE: ____________________________ BRAND:___________________________________ COOLANT MIXTURE: ______________________________ BRAND:___________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ ______________________________________________
REV: A PART NO: 33701 11.25.
