DIESEL GENERATOR MMG130D • MMG175 • MMG205 · Parts manuals available online! POWER PRODUCTS LLC DIESEL GENERATOR 175 With ControllerTM 00382 MMG130D • MMG175 • MMG205

Parts manuals available online! www.m-p-llc.com

POWER PRODUCTS LLC

DIESEL GENERATOR

175

With ControllerTM

00382

MMG130D • MMG175 • MMG205

OPERATING MANUAL

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.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.

Read all of the manuals included with the unit. Each manual details specific information regarding items such as setup, use and service requirements. An engine operator’s manual provides detailed operation and maintenance procedures for the engine. Additional copies of the engine operator’s manual are available from the engine manufacturer.

DO NOT MODIFY or use this equipment for any application other than which it was designed for.

Magnum Power Products LLC recommends that a trained and licensed professional perform all electrical wiring and testing functions. Installation should be in compliance with the National Electrical Code (NEC), state and local regulations and Occupational Safety and Health Association (OSHA) guidelines.

MAGNUM POWER PRODUCTS LLC215 Power Drive • Berlin, WI 54923

U.S.A.Phone: 920-361-4442

FAX: 920-361-4416Toll 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.

To ORDER SERVICE PARTS, please contact the dealer from which you purchased the unit, or call Magnum Power Products LLC to locate a dealer in your area.

Engine Make:__________________________________________

Engine Serial Number:___________________________________

Engine Model Number: __________________________________

Generator Make: _______________________________________

Generator Model Number:________________________________

Generator Serial Number: ________________________________

Unit Model Number:_____________________________________

Unit Serial Number: _____________________________________

WARNINGCALIFORNIA PROPOSITION 65 WARNING: Diesel engine exhaust and some of its

constituents are known to the state of California to cause cancer, birth defects and other reproductive harm.

2

TABLE OF CONTENTSPage

INTRODUCTION ................................................................................................................................ 2SAFETY NOTES ................................................................................................................................ 6OPERATING SAFETY ....................................................................................................................... 6ENGINE SAFETY............................................................................................................................... 7ELECTRICAL SAFETY ...................................................................................................................... 7TOWING SAFETY.............................................................................................................................. 8REPORTING TRAILER SAFETY DEFECTS ..................................................................................... 8SAFETY SYMBOL SUMMARY .......................................................................................................... 9SPECIFICATIONS - MMG130D ....................................................................................................... 10SPECIFICATIONS - MMG175.......................................................................................................... 11SPECIFICATIONS - MMG205.......................................................................................................... 12UNIT DIMENSIONS ......................................................................................................................... 13UNIT SERIAL NUMBER LOCATIONS ............................................................................................ 14COMPONENT LOCATIONS ............................................................................................................ 15MAIN CONTROL PANEL FEATURES ............................................................................................. 16MAIN CONTROL PANEL FEATURES - WITH CAM LOCK OPTION .............................................. 18POWER ZONE™ CONTROLLER.................................................................................................... 20CONTROLLER FEATURES AND FUNCTIONS .............................................................................. 20OPERATOR SCREENS ................................................................................................................... 21MAINTENANCE SCREENS ............................................................................................................. 23GENERATOR MONITORING .......................................................................................................... 26ENGINE MONITORING ................................................................................................................... 26DIESEL EXHAUST FILTER MONITORING ..................................................................................... 26POWER ZONE™ CONTROLLER INFORMATION DISPLAYS, FUNCTIONS, AND RESET ......... 27GENERATOR OUTPUT CONNECTION LUGS ............................................................................... 28GENERATOR CAM LOCK CONNECTION(S) OPTION .................................................................. 28VOLTAGE SELECTOR SWITCH ..................................................................................................... 29PRESTART CHECKLIST ................................................................................................................. 31ENGINE BREAK-IN REQUIREMENTS............................................................................................ 31EMERGENCY STOP SWITCH ........................................................................................................ 31MANUAL STARTING OF THE UNIT................................................................................................ 32AUTO (REMOTE) STARTING OF THE UNIT .................................................................................. 33VOLTAGE REGULATION ................................................................................................................ 33DERATING FOR ALTITUDE ............................................................................................................ 34WET STACKING .............................................................................................................................. 34CONTROL PANEL RECEPTACLES................................................................................................ 34MAIN CIRCUIT BREAKER............................................................................................................... 35REMOTE START TERMINAL BLOCK ............................................................................................. 35TRANSFER SWITCH ....................................................................................................................... 35AUTO EXERCISE TIMER ................................................................................................................ 36FINE VOLTAGE ADJUSTMENT ...................................................................................................... 38SHUTTING DOWN THE UNIT ......................................................................................................... 38EXHAUST FILTER CLEANING OPERATIONS ............................................................................... 38TOWING THE UNIT ......................................................................................................................... 39LIFTING THE UNIT .......................................................................................................................... 40DAILY WALK AROUND INSPECTION ............................................................................................ 40GENERAL MAINTENANCE ............................................................................................................. 40BASIC MAINTENANCE SCHEDULE - JOHN DEERE ENGINE...................................................... 41RESETTING THE MAINTENANCE ALARMS.................................................................................. 42BELT TENSIONERS ........................................................................................................................ 43EXHAUST FILTER SERVICE REQUIREMENTS ............................................................................ 43ECU OVERRIDE SWITCH ............................................................................................................... 43CHECKING GENERATOR DRIVE PLATE TORQUE ...................................................................... 43JACK MAINTENANCE ..................................................................................................................... 44TRAILER WHEEL BEARINGS ......................................................................................................... 44TROUBLESHOOTING AUTOMATIC SHUTDOWN CONDITIONS ................................................. 44VISCOUS FAN CLUTCH OPTION................................................................................................... 46AC WIRING DIAGRAM - 3 POSITION VOLTAGE SELECTOR SWITCH - MMG130D................... 47

3

AC WIRING DIAGRAM - 3 POSITION VOLTAGE SELECTOR SWITCH - MMG175 ..................... 48AC WIRING DIAGRAM - 3 POSITION VOLTAGE SELECTOR SWITCH - MMG205 ..................... 49AC WIRING DIAGRAM - 4-POS. VOLT. SELECTOR SWITCH OPTION - MMG130D, MMG175 .. 50AC WIRING DIAGRAM - 4-POS. VOLT. SELECTOR SWITCH OPTION - MMG205...................... 51AC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT................................................................ 52DC WIRING DIAGRAM .................................................................................................................... 53DC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT................................................................ 54WIRING BLOCK DIAGRAM - DEDICATED 12 LEAD GENERATORS OPTION............................. 55TRAILER LIGHTS WIRING DIAGRAM ............................................................................................ 56WIRING HARNESS - ELECTRIC BRAKE OPTION......................................................................... 57SERVICE LOG ................................................................................................................................. 58

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This Page Intentionally Left Blank

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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. The following formatting options will apply when calling the reader’s attention to the DANGERS, WARNINGS, CAUTIONS, NOTICES and NOTES.

DANGERINDICATES A HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN

DEATH OR SERIOUS INJURY.

WARNINGIndicates a hazardous situation which, if not avoided, could result in death or serious

injury.

CAUTIONIndicates a hazardous situation which, if not avoided, may result in minor or moderate injury.

Indicates a hazardous situation which, if not avoided, may result in property or equipment damage.

Note: Notes contain additional information important to a procedure and will be found within the regular text body of this manual.

OPERATING SAFETY

Before using the generator, be sure to read and understand all of the instructions. This equipment was designed for specific applications; DO NOT modify or use this equipment for 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 and controls. Inexperienced operators should receive instruction from someone familiar with the equipment before being allowed to operate or set up the generator. The following points should be practiced at all times:

• The area immediately surrounding the generator should be dry, clean, and free of debris.

• NEVER start a unit in need of repair.

• Make certain the generator is securely fastened to a good earthen ground before use.

• NEVER operate the unit on a combustible surface.

• NEVER operate the generator if any of the following conditions exist during operation:

1. Noticeable change in engine speed.

2. Loss of electrical output.

3. Equipment connected to the generator overheats.

4. Sparking occurs.

5. Engine misfires or there is excessive engine/generator vibration.

6. Protective covers are loose or missing.

7. If the ambient air temperature is above 120°F (49°C).

6

• Make sure slings, chains, hooks, ramps, jacks, and other types of lifting devices are attached securely and have enough weight-bearing capacity to lift or hold the equipment safely. Always remain aware of the position of other people around you when lifting the equipment.

• NEVER operate a unit while tired, distracted, or under the influence of drugs or alcohol.

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. Diesel engine exhaust contains carbon monoxide, a deadly, odorless and colorless gas which, if inhaled, can cause nausea, fainting or death. Only use this unit outside and away from windows, doors, and ventilation equipment.

• DO NOT fill fuel tank near an open flame, while smoking, or while engine is running. DO NOT fill tank in an enclosed area with poor ventilation.

• DO NOT operate with the fuel tank cap loose or missing.

• DO NOT touch or lean against hot exhaust pipes or engine cylinders.

• DO NOT clean air filter with gasoline or other types of low flash point solvents.

• DO NOT remove engine coolant cap while engine is hot.

• DO NOT operate the unit without a functional exhaust system. Prolonged exposure to sound levels in excess of 85 dB(A) can cause permanent hearing loss. Wear hearing protection when working around a running engine.

• Keep hands, feet and loose clothing away from moving parts on the generator and engine.

• Keep area around exhaust pipes and air ducts free of debris to reduce the chance of an accidental fire.

• Batteries contain sulfuric acid which can cause severe injury or death. Sulfuric acid can 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 lethal voltages are present at the 120V Ground Fault Circuit Interrupt (GFCI) receptacles and the 240V twist-lock receptacles located on the control panel, and at the connection lugs and optional cam lock receptacles. Failure to follow the safety guidelines described below could result in severe injury or death.

• Only a qualified and licensed electrician should make connections to the generator.

• NEVER wash the unit with high pressure hoses or power washers.

• NEVER start the unit under load. The circuit breakers must be in the OFF (O) position when starting the unit in Manual mode. The circuit breakers can be in the ON (I) position only when started in the Auto mode. A transfer switch must be used in the Auto mode to deflect the load upon startup.

• ALWAYS disconnect the negative (-) battery cable from the corresponding terminal before performing any service on the engine, generator, or any other components. Remove the negative (-) battery cable from the corresponding terminal if the unit is to be stored or transported.

• ALWAYS use extreme caution when servicing this unit in damp conditions. Do not service the unit if your skin or clothing is wet. Do not allow water to collect around the base of the unit.

• ALWAYS connect the unit to a good earthen ground before use. Follow all the National Electrical Code (NEC), state and local regulations.

7

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).

• Check tires on trailer for tread wear, inflation, and condition.

• NEVER tow trailer using defective parts. Inspect the hitch and coupling for wear or damage.

• Make sure the trailer hitch and the coupling are compatible. Make sure the coupling is securely fastened to the vehicle.

• Connect safety chains in a crossing pattern under the tongue and ATTACH THE BREAKAWAY CABLE TO THE REAR BUMPER OF THE TOWING VEHICLE. Do not attach the cable to the trailer hitch.

• Make sure directional and brake lights on the trailer are connected and working properly.

• Check that lug nuts holding wheels are tight and that none are missing.

• 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.

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 trailer, a large angle between the trailer and tow vehicle will cause more weight to be carried by one axle, which could cause premature wear on the tires and axles and cause potentially unsafe operating conditions.

The trailer is equipped with hydraulic surge brakes or electric surge brakes. Check the operation of the brakes by braking the vehicle at a slow speed before entering traffic. Both the trailer and the vehicle should brake smoothly. If the trailer seems to be pushing, check the level in the surge brake fluid reservoir.

When towing, maintain extra space between vehicles and avoid soft shoulders, curbs and sudden lane changes. If you have not pulled a trailer before, practice turning, stopping, and backing up in an area away from heavy traffic.

A film of grease on the coupler will extend coupler life and eliminate squeaking. Wipe the coupler clean and apply fresh grease each time the trailer is towed.

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. However, NHTSA cannot become involved in individual problems 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:

AdministratorNHTSA1200 New Jersey Avenue S.E.Washington, DC 20590

You can also obtain other information about motor vehicle safety from http://www.safercar.gov.

8

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.

Dangerous voltage may bepresent.Hot surface(s) nearby.

Anchor/tie down point.Belt/entanglement hazard; keep body parts clear of this area.

Fan hazard; keep body parts clear of this 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 you to potential personal injury hazards.

Read and understand the supplied operator’s manual before operating unit.

Stop engine before fueling.

Unit electrical ground.Hearing protection requiredwhile operating unit with doors open.

Burn/scald hazard; pressurized steam.Engine running.

Exhaust Filter Cleaning enabled. Exhaust Filter Cleaning disabled.

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SPECIFICATIONS - MMG130D

MAGNUM MODEL MMG130D MMG130D Super Start

EngineMake/Brand...................................................................... John Deere ...................................John DeereModel ............................................................................... PE4045HFG93..............................PE4045HFG93EPA Tier ........................................................................... 4i ...................................................4iHorsepower - prime hp (kW) .......................................... 152 (113).......................................152 (113)Horsepower - standby hp (kW) ....................................... 166 (124).......................................166 (124)Operating Speed rpm ..................................................... 1800 ..............................................1800Displacement in3 (L) ........................................................ 275 (4.5)........................................275 (4.5)Cylinders - qty .................................................................. 4 ....................................................4Fuel Consumption - 100% prime gph (Lph) ................... 7.4 (28.0).......................................7.4 (28.0)Battery Type..................................................................... Group 24 .......................................Group 24Battery Voltage (Quantity per Unit) .................................. 12V (1) ..........................................12V (1)Battery Rating .................................................................. 1000 CCA .....................................1000 CCA

GeneratorMake/Brand...................................................................... Marathon Electric ..........................Marathon ElectricModel ............................................................................... 363PSL1607 .................................431CSL6206Type, Insulation................................................................ Brushless, H..................................Brushless, H

Generator Set (Engine/Generator)3Ø - Standby kW (kVA) ................................................... 107 (134).......................................110 (138)Amps - 3Ø Standby 480V (208V) A ................................ 161 (372).......................................166 (383)3Ø - Prime kW (kVA) ...................................................... 98 (122).........................................100 (125)Amps - 3Ø Prime 480V (208V) A .................................... 147 (339).......................................150 (347)1Ø - Standby kW (kVA) ................................................... 96 (96)...........................................108 (108)Amps - 1Ø Standby - 240V A .......................................... 400 ................................................4501Ø - Prime kW (kVA) ...................................................... 90 (90)...........................................98 (98)Amps - 1Ø Prime - 240V A ............................................. 375 ................................................408Frequency Hz .................................................................. 60 ..................................................60Power Factor.................................................................... 1 (1Ø), 0.8 (3Ø).............................1 (1Ø), 0.8 (3Ø)Sound dB(A) 23 ft @ prime ............................................ 68 ..................................................68

WeightsDry Weight, Skid Mounted lbs (kg) ................................. 5444 (2469)...................................5909 (2680)Operating Weight, Skid Mounted lbs (kg) ...................... 7929 (3596)...................................8394 (3807)Dry Weight, Trailer Mounted* lbs (kg) ............................ 6840 (3102)...................................7305 (3313)Operating Weight, Trailer Mounted* lbs (kg) .................. 9325 (4230)...................................9790 (4441)*Standard trailer only. Consult factory for custom trailer weights.

CapacitiesFuel Tank Volume gal (L) ................................................ 342 (1295).....................................342 (1295)Usable Fuel Volume gal (L) ............................................ 313 (1185).....................................313 (1185)Coolant (incl. engine) qt (L) ............................................ 31.5 (29.8).....................................31.5 (29.8)Oil (incl. filter) qt (L) ........................................................ 33.0 (31.2).....................................33.0 (31.2)Maximum Run Time hrs ................................................. 44 ..................................................44

AC DistributionCircuit Breaker Size ......................................................... 450 ................................................450Voltage Selection ............................................................. 3 Position Switch (lockable) ..........3 Position Switch (lockable)Voltage Regulation........................................................... +/- 0.5% ........................................+/- 0.5%Voltages Available 1Ø...................................................... 120, 139, 208, 220, 240, 277 ........120, 139, 208, 220, 240, 277Voltages Available 3Ø...................................................... 208, 220, 440, 480 ........................208, 220, 440, 480

TrailerNumber of Axles .............................................................. 2 ....................................................2Capacity - Axle Rating lbs (kg) ....................................... 6000 (2722)...................................6000 (2722)Tire Size in ...................................................................... 16 ..................................................16Brakes.............................................................................. Surge ............................................SurgeHitch - Standard ............................................................... 3" Ring ..........................................3" RingMaximum Tire Pressure psi ............................................ 75 ..................................................75

Specifications are subject to change without notice.

10

SPECIFICATIONS - MMG175

MAGNUM MODEL MMG175 MMG175 Super Start

EngineMake/Brand...................................................................... John Deere ...................................John DeereModel ............................................................................... PE6068HFG94..............................PE6068HFG94EPA Tier ........................................................................... 4i ...................................................4iHorsepower - prime hp (kW) .......................................... 217 (162).......................................217 (162)Horsepower - standby hp (kW) ....................................... 241 (180).......................................241 (180)Operating Speed rpm ..................................................... 1800 ..............................................1800Displacement in3 (L) ....................................................... 415 (6.8)........................................415 (6.8)Cylinders - qty .................................................................. 6 ....................................................6Fuel Consumption - 100% prime gph (Lph) ................... 10.9 (41.3).....................................10.9 (41.3)Battery Type..................................................................... Group 31 .......................................Group 31Battery Voltage (Quantity per Unit) .................................. 12V (1) ..........................................12V (1)Battery Rating .................................................................. 1000 CCA .....................................1000 CCA

GeneratorMake/Brand...................................................................... Marathon Electric ..........................Marathon ElectricModel ............................................................................... 431PSL6306 .................................432PSL6210Type, Insulation................................................................ Brushless, H..................................Brushless, H

Generator Set (Engine/Generator)3Ø - Standby kW (kVA) ................................................... 153 (191).......................................161 (201)Amps - 3Ø Standby 480V (208V) A ................................ 230 (530).......................................242 (558)3Ø - Prime kW (kVA) ...................................................... 138 (172).......................................145 (181)Amps - 3Ø Prime 480V (208V) A .................................... 207 (477).......................................218 (502)1Ø - Standby kW (kVA) ................................................... 125 (125).......................................157 (157)Amps - 1Ø Standby - 240V A .......................................... 521 ................................................6541Ø - Prime kW (kVA) ...................................................... 120 (120).......................................143 (143)Amps - 1Ø Prime - 240V A ............................................. 500 ................................................596Frequency Hz .................................................................. 60 ..................................................60Power Factor.................................................................... 1 (1Ø), 0.8 (3Ø).............................1 (1Ø), 0.8 (3Ø)Sound dB(A) 23 ft @ prime ............................................ 68 ..................................................68

WeightsDry Weight, Skid Mounted lbs (kg) ................................. 6604 (2996)...................................7069 (3206)Operating Weight, Skid Mounted lbs (kg) ...................... 9032 (4097)...................................9497 (4307)Dry Weight, Trailer Mounted* lbs (kg) ............................ 8000 (3629)...................................8465 (1646)Operating Weight, Trailer Mounted* lbs (kg) .................. 10428 (4730).................................10893 (4941)*Standard trailer only. Consult factory for custom trailer weights.





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SPECIFICATIONS - MMG205

MAGNUM MODEL MMG205 MMG205 Super Start

EngineMake/Brand...................................................................... John Deere ...................................John DeereModel ............................................................................... PE6068HFG95..............................PE6068HFG95EPA Tier ........................................................................... 4i ...................................................4iHorsepower - prime hp (kW) .......................................... 252 (188).......................................252 (188)Horsepower - standby hp (kW) ....................................... 268 (200).......................................268 (200)Operating Speed rpm ..................................................... 1800 ..............................................1800Displacement in3 (L) ....................................................... 415 (6.8)........................................415 (6.8)Cylinders - qty .................................................................. 6 ....................................................6Fuel Consumption - 100% prime gph (Lph) ................... 12.8 (48.5).....................................12.8 (48.5)Battery Type..................................................................... Group 31 .......................................Group 31Battery Voltage (Quantity per Unit) .................................. 12V (1) ..........................................12V (1)Battery Rating .................................................................. 1000 CCA .....................................1000 CCA

GeneratorMake/Brand...................................................................... Marathon Electric ..........................Marathon ElectricModel ............................................................................... 431PSL6336 .................................433PSL6216 Type, Insulation................................................................ Brushless, H..................................Brushless, H

Generator Set (Engine/Generator)3Ø - Standby kW (kVA) ................................................... 174 (217).......................................178 (222)Amps - 3Ø Standby 480V (208V) A ................................ 261 (602).......................................267 (616)3Ø - Prime kW (kVA) ...................................................... 164 (205).......................................166 (208)Amps - 3Ø Prime 480V (208V) A .................................... 247 (569).......................................250 (577)1Ø - Standby kW (kVA) ................................................... 155 ................................................176Amps - 1Ø Standby - 240V A .......................................... 646 ................................................7331Ø - Prime kW (kVA) ...................................................... 142 ................................................167Amps - 1Ø Prime - 240V A ............................................. 592 ................................................696Frequency Hz .................................................................. 60 ..................................................60Power Factor.................................................................... 1 (1Ø), 0.8 (3Ø).............................1 (1Ø), 0.8 (3Ø)Sound dB(A) 23 ft @ prime ............................................ 68 ..................................................68

WeightsDry Weight, Skid Mounted lbs (kg) ................................. 6624 (3005)...................................7444 (3377)Operating Weight, Skid Mounted lbs (kg) ...................... 9052 (4106)...................................9872 (4478)Dry Weight, Trailer Mounted* lbs (kg) ............................ 8020 (3638)...................................8840 (4010)Operating Weight, Trailer Mounted* lbs (kg) .................. 10448 (4739).................................11268 (5111)*Standard trailer only. Consult factory for custom trailer weights.





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UNIT DIMENSIONS

MAGNUM MODEL MMG130D, MMG175, MMG205

Dimensions (L x W x H)Skid Mounted in (m) ..................................................................................................... 144 x 50 x 77 (3.66 x 1.27 x 1.96)Trailer Mounted in (m) .................................................................................................. 210 x 86 x 93 (5.33 x 2.18 x 2.36)


W L

H

W L

H

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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.

VIN Tag (located on opposite side of trailer)

UNIT ID Tag TIRE AND LOADING INFORMATIONRENSEIGNEMENTS SUR LES PNEUS ET LE CHARGEMENT

SEE OWNER’SMANUAL FOR ADDITIONAL

INFORMATIONVOIR LE

MANUEL DEL’USAGER

POURPLUS DE

RENSEIGNEMENTS

MANUFACTURED BY/FABRIQUE PAR: Magnum Power Products LLC DATE: 00/0000GVWR/PNBV: 000KG (0000LBS) COLD INF. PRESS./ PRESS. DE

V.I.N./N.I.V.:

00000000000000000

TYPE:

TRAILER

MODEL:

XXX000

GAWR / PNBE TIRE / PNEU RIM / JANTE GONF A FROID - KPA(PSI/LPC) SGL / DUAL

EACHAXLE

THIS VEHICLE CONFORMS TO ALL APPLICABLE STANDARDS PRESCRIBED UNDER THE U.S. FEDERAL MOTOR VEHICLE SAFETY STANDARDS(FMVSS) AND CANADIAN MOTOR VEHICLE SAFETY REGULATIONS IN EFFECT ON THE DATE OF MANUFACTURE.

CE VEHICULE EST CONFORME A TOUTES LES NORMES QUI LUI SONT APPLICABLES EN VERTU DU REGLEMENT SUR LA SECURITE DES VEHICULES AUTOMOBILES DU CANADA EN VIGUEUR A LA DATE SA FABRICATION.

The weight of cargo should never exceed 0000KG (0000LBS)Le poids du chargement ne doit jamais depasser 0000KG (0000LBS)

00385

Serial Number

V

A

Model

KVA

Manufacturing Code

1 ph. 1.0PF 3 ph. .8PF 3 ph. 1.0PF

KW

Country of Origin

Weight (lbs/kg) RPM/Frequency

Rating

Ins. Class

FOR ELECTRICAL EQUIPMENTONLY. POUR MATERIAL

ELECTRIQUE SEULEMENT.209649

Form: SFC626B

Manufactured by Magnum Power Products, LLC.,a subsidiary of Generac Power Systems, Inc.

(920) 361-4442 (800) 926-9768

14

COMPONENT LOCATIONS

EngineAccess

CentralLift Point

Voltage SelectorAccess

Fuel Fill

Engine BatteryAccess

Ladder

RadiatorAccess Panel

EngineExhaust

Ladder

EngineAccess

RadiatorDrain Port

Oil DrainPort

EmergencyStop

ControlPanel

Access

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15

MAIN CONTROL PANEL FEATURES

2

9 81011

12

13

14

15

3

4

1

7

5

6

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1. DOCUMENT HOLDER

2. POWER ZONE™ CONTROLLER: Refer to “Power Zone™ Controller” on page 20.

3. AUXILIARY LIGHT SWITCHES (2) (Optional): These switches operate the control panel and interior lights.

4. 50A CIRCUIT BREAKERS (3): Circuit breakers for the 120/240V twist-lock receptacles.

5. 120V GFCI RECEPTACLES (2): Receptacles for additional equipment that may require Ground Fault Circuit Interrupt (GFCI) protection.

6. 20A CIRCUIT BREAKERS (2): Circuit breakers for the 120V GFCI receptacles.

7. REMOTE START TERMINAL BLOCK: Used to connect the generator to a dry-contact closure switch for remote starting of the unit.

8. CONNECTION FOR BATTERY CHARGER (Optional): Allows for 120VAC input to power an onboard battery charger.

9. 120/240V TWIST-LOCK RECEPTACLES (3): These receptacles are used for connecting additional loads or equipment to the generator in 240 and 208 voltage selections only.

10. CONNECTION FOR ENGINE BLOCK HEATER (Optional): Allows for 120VAC input to power the engine block heater.

11. DOOR SAFETY SWITCH: The connection lug door is equipped with a safety interlock switch that will trip the main circuit breaker and disable the voltage regulator if the door is opened while the unit is operating.

12. OUTPUT GROUND CONNECTION: Ground lug for attaching the generator to a good earthen ground.

13. CONNECTION TERMINAL LUGS (4): External loads can be wired to these lugs.

14. DIESEL EXHAUST FILTER CLEANING SWITCH: This switch toggles between enabling or disabling the auto exhaust cleaning feature and entering manual regeneration. For additional information, refer to “Exhaust Filter Cleaning Operations” on page 38.

15. MAIN CIRCUIT BREAKER FOR CONNECTION LUGS: This breaker will disconnect power to the connection lugs (items 12-13). It WILL NOT disconnect power to the receptacles when the engine is running. The main circuit breaker will trip in order to protect the generator from damage if a load is too great.

17

MAIN CONTROL PANEL FEATURES - WITH CAM LOCK OPTION

12

3

81011

13

16

15

6

7

14

12

4

5

9 00388

18

1. DOCUMENT HOLDER

2. POWER ZONE™ CONTROLLER: Refer to “Power Zone™ Controller” on page 20.

3. AUXILIARY LIGHT SWITCHES (2) (Optional): These switches operate the control panel and interior lights.

4. 120V GFCI RECEPTACLES (2): Receptacles for additional equipment that may require Ground Fault Circuit Interrupt (GFCI) protection.

5. 50A CIRCUIT BREAKERS (3): Circuit breakers for the 120/240V twist-lock receptacles.

6. REMOTE START TERMINAL BLOCK: Used to connect the generator to a dry-contact closure switch for remote starting of the unit.

7. CAM LOCK CONNECTORS (10) (Optional): Series 16 taper nose 400A/600V cam locks are connected here. (Green) Cam lock ground connection for attaching the generator to a good earthen ground. For additonal information, refer to “Generator Cam Lock Connection(s) Option” on page 28.

8. CONNECTION FOR BATTERY CHARGER (Optional): Allows for 120VAC input to power onboard battery charger.

9. 120/240V TWIST-LOCK RECEPTACLES (3): These receptacles are used for connecting additional loads or equipment to the generator in the 240 and 208 voltage selections only.

10. CONNECTION FOR ENGINE BLOCK HEATER (Optional): Allows for 120VAC input to power the engine block heater.

11. DOOR SAFETY SWITCH: The connection lug door and cam lock door are equipped with a safety interlock switch that will trip the main circuit breaker and disable the voltage regulator if the doors are opened while the unit is operating.

12. OUTPUT GROUND CONNECTION: Ground lug for attaching the generator to a good earthen ground.

13. CONNECTION TERMINAL LUGS (4): External loads can be wired to these lugs.

14. 20A CIRCUIT BREAKERS (2): Circuit breakers for the 120V GFCI receptacles.

15. MAIN CIRCUIT BREAKER FOR CONNECTION LUGS: This breaker will disconnect power to the connection lugs (items 12-13). It WILL NOT disconnect power to the receptacles when the engine is running. The main circuit breaker will trip in order to protect the generator from damage if a load is too great.

16. DIESEL EXHAUST FILTER CLEANING SWITCH: This switch toggles between enabling or disabling the auto exhaust cleaning feature and entering manual regeneration. For additional information, refer to “Exhaust Filter Cleaning Operations” on page 38.

19

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 based on 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. When a fault condition occurs, the engine can be shut down automatically and the LCD window will show the fault that caused the shut down; to resume operation, the fault condition must be resolved.

This controller also records a history of unit performance which may be viewed at any time and will not be lost when the controller is powered down.

CONTROLLER FEATURES AND FUNCTIONS

OPERATOR SCREENS

These buttons are used to enter the various operator screens from any other screen. The operator screens consists of four screens: Home ( ), Engine ( ), Generator ( ), and Voltage Adjust ( ). For information about the screens, refer to “Operator Screens” on page 21.

ALARM MUTE

The Alarm Mute ( ) button silences the audible alarm. Additional action will be required to fully disable the active alarm.

AUTO/MANUAL MODE

The Auto/Manual Mode ( ) button is used to change the startup and shutdown modes of the unit. When pressed once, the unit enters Manual mode and when pressed and held for five seconds, the unit enters Auto mode. If in Auto mode, pressing once will return the unit to Manual mode.

NAVIGATION BUTTONS

These buttons are used to navigate and interact with the Power Zone™ controller screens. Pressing any directional arrow (▲, ►, ▼, ◄) while on any of the operator screens will open the maintenance screens, and navigate the tabs and pages within the maintenance screens. The Enter () button is used to select menus, confirm alarms, and confirm altered settings.

CONTROL ON

CONTROL OFF

I

O

Power Zone™ ControllerSTARTING THE GENERATORDAS STARTEN DES GENERATORSCOMIENZO DEL GENERADORCOMMENCEMENT DU GÉNÉRATEUR

1. PRESS CONTROL POWER SWITCH “ON”

2. PUSH ENGINE START “I”

CONTROLCONTROLONON

CONTROLCONTROLOFFOFF

I

O

STOPPING THE GENERATORDAS AUFHÖREN DES GENERATORSPARADA DEL GENERADORARRÊT DU GÉNÉRATEUR

1. PUSH ENGINE STOP “O”

2. PRESS CONTROL POWER SWITCH “OFF”

CONTROLCONTROLONON

CONTROLCONTROLOFFOFF

I

O

Home

Engine

Voltage

Generator

Auto /Manual

Mode

AlarmMute

LCD Window

NavigationButtons

ControlPowerSwitch

Engine Start(Manual Mode)

Engine Stop / Reset

OperatorScreens

00389

GEN V+ -

20

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 (I) button has no effect.

ENGINE STOP/RESET

Pressing the Engine Stop/Reset (O) button will shut down the unit and put the controller into Stop mode, whether in Manual mode or Auto mode.

CAUTIONIn case of an emergency, always press the emergency stop switch located on the side of the unit to stop the engine immediately. The Engine Stop/Reset (O) button may delay the

engine shutdown if stop faults exist.

To prevent damage to the generator and connected equipment, remove all loads from the generator by opening all circuit breakers (turn to the OFF (O) position) before pressing the

Engine Stop/Reset (O) button.

THE LIQUID CRYSTAL DISPLAY (LCD)

This window will display the various operator and maintenance screens. By viewing these screens, the operator will be able to monitor both the engine and generator status while the unit is running.

OPERATOR SCREENS

The operator screens display the most relevant and critical information an operator will need to properly configure and utilize a unit. From these four screens, the operator can access engine, generator and power transmission information necessary to operate the unit under normal conditions.

HOME SCREEN

The Home screen is the default screen of the controller and will display after the controller is powered up and the unit management software is loaded. It displays a live readout of the kW meter, percent of load used (gauge), selected phase, volts and amps being produced by the generator, and the fuel level with time until empty. The controller will automatically return to this screen from any other screen after a period of inactivity.

00393

Manual Mode

3 PHASEVolts

Amps

480

128

106.9 kW

%

0

10

100 110

20

30

4050

6070

8090

Time to Empty15 hr

Full

3/4

1/2

1/4

Empty

74

%

GEN

V+ -

21

ENGINE SCREEN

The Engine screen displays the oil pressure, coolant temperature and battery voltage on three main gauges. Below the gauges is an hour gauge displaying the total run time on the engine. At the bottom of the screen, this screen also displays maintenance alarm status with the time remaining (black text) or the time past (red text) a scheduled maintenance tasks, along with the 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 (0-689 kPa). Normal operating pressure is between 35-80 psi (241-552 kPa).

• Coolant Temp: Displays engine coolant temperature. Current coolant temperature is displayed directly below the gauge at all times. The gauge displays coolant temperature between 150°-250°F (66°-121°C). Normal operating temperature of the unit is between 180°-200°F (82°-93°C) with an average ambient air temperature of 70°F (21°C).

• Battery: Displays the engine battery voltage. Current battery voltage is displayed directly below the gauge at all times. The gauge displays battery voltage between 0-50V. A normal reading is 12-14V on 12 volt systems and 24-26V on 24 volt systems (with the engine running).

GENERATOR SCREEN

The Generator screen displays the average voltage frequency, volts and amps from the generator, as well as line-to-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.

Note: When loading the generator, it is important to observe the amperage to determine the load balance on each line of the generator. Minor load unbalances, usually ten percent or less, will not cause any particular problems. Every effort should be made to distribute the load equally between all lines.

00394

GEN

V+ -

MaintenanceAlarm Hours Description Action

1 174 To Service Oil Maintenance2 174 To Service Fuel Maintenance3 174 To Service Air Maintenance

Oil press. Coolant Temp. Battery

Manual Mode

Hrs

13.8 V

0

10

20 30

40

50150

170

190 210

230

250

°F214PSI50.91000

20

40 60

80

0 0 3 2 5 1 5

WarningShutdown

Electrical Trip

00395

Manual Mode

GEN

V+ -

Parallel Low Zig-Zag

L1 (U)

L2 (W)

N

Volt Volt Amp kW

L1-L2 L1

L2-L3 L2

L3-L1 L3

IE

000

000

0

05025

0.00.00.0

AmpVoltFreq0

10

20

30 40

50

60

70 0

88

175

263

350 0

13

25

38

50

22

• Freq: Displays the output frequency in Hertz (Hz). Normal operating frequency is 60 Hz.• Volts: Displays the nominal voltage in Volts (V).• Amps: Displays the AC output amperage produced by the generator in Amps (A).

Additional information can be found on the electric power table at the bottom-left side of the screen. This provides an overview of all three lines and average voltage and amperage readouts.

VOLTAGE ADJUST SCREEN

The Voltage Adjust screen displays the line-to-neutral and line-to-line voltage averages. The operator can electron-ically adjust the voltage within limits to prevent under-voltage or over-voltage conditions using the on-screen instructions. This feature replaces a traditional potentiometer. Refer to “Fine Voltage Adjustment” on page 38 for more information.

MAINTENANCE SCREENS

All of the data inputs from the engine, generator, inputs/outputs, schedule and Power Zone™ controller are visible on the maintenance screens.

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 (▲, ►, ▼, ◄).

The bottom of the screens have a list of available tabs, with the currently displayed tab highlighted in blue. The tabs can be selected by using the ▲ or ▼ buttons. To the left of the tabs, the current/available pages are displayed. The pages within a tab can be viewed by using the ▲ and ▼ buttons. Whenever a new tab is selected, the current page will always be page 1.

GENERATOR SUMMARY

The Generator Summary can be found at the top of all maintenance screens and provides an overview of the system.

ENGINE TAB

The Engine tab contains maintenance and instrumentation data gathered from the engine itself. Above the engine analogue meters is a row of alarm icons. Each icon can be one of three colors: grey (inactive), yellow (warning) or red (shutdown). The alarm icons are as follows from left to right: water in fuel, emission filter, engine air inlet temperature, charge alternator, oil pressure, fuel level, battery voltage, coolant temperature, and ECU lamp.

00396

Manual Mode

GEN

V+ -

Voltage Adjust

- Press , voltage will begin flashing- Use and arrows to adjust voltage- Press to confirm new voltage. Numbers will stop flashing

V L-N Average

L-L AverageV

480277

00397

SITE GENSET 7741 \ 774007:10480V/277V 3-Phase

Return Delay 10:00:00 Total GeneratorkWh+

kVAhkVArhpf

kVArkVAkW

%

0.0

0.0

0.0%

0.00.0

0.00.0

0.00

0.00.0Hz

kWkVAr

23

Note: The content may change depending upon the selected engine and the features supported by the engine.

GENERATOR TAB

The Generator tab contains maintenance and instrumentation data gathered from the generator. Each page highlights different data gathered by the generator with the analogue meters changing accordingly. The last two pages will display the information in the bar graph. The bar graph shows blue for positive and red for negative. For the power factor bar graph, blue is for lagging pf and red is for leading pf.

Note: The content may change depending upon the selected generator and the features supported by the generator.

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.

00396

GEN

V+ -


Return Delay 10:00:00

0.0 Hz

Total GeneratorkWh+

kVAhkVArh

kWkVAkVArpf

0.0

0.00.0

0.00.00.0

0.000.0 %

%0.0kW

kVAr

StatusScheduleI/OAlarmsEngine Generator1/9

Engine Starts

Fuel Used

Fuel RemainingUS Gal

Litre

HrsRPM0

0 0 0 0 0 0 0 Oil press. Coolant Temp.

Charge AltBatteryOil Temp

Fuel Level

0 °F V

%0 °FPSI

0.0 V0.0

00.00

0

10

20 30

40

500

10

20 30

40

50

0

2

4 6

8

10 -50

0

50 150

200

250 0

20

40 60

80

100

10

30

90

7050

1

35

7

9

100

-50

0

50 150

200

250

100

CAN

0

3

69

12 1518

21

24

27

15

30

3336

00399

GEN

V+ -



0.0 Hz

Total GeneratorkWh+

kVAhkVArh

kWkVAkVArpf

0.0

0.00.0

0.00.00.0

0.000.0 %

%0.0kW

kVAr


L1-L2

L2-L3

L3-L1

L1

L2

L3

IE

Volt Volt Amp kW kVA kVAr pf0.00.00.0

0.00.00.0

0.00.00.0

0.00.00.0

00

000 0

0

000

L1-L2 L2-L3 L3-L1 Hz

FreqVoltVoltVolt0

100

200

300

400

500

600 0

100

200

300

400

500

600 0

100

200

300

400

500

600 0

10

20

30 40

50

60

70

00400

GEN

V+ -



0.0 Hz

Total GeneratorkWh+

kVAhkVArh

kWkVAkVArpf

0.0

0.00.0

0.00.00.0

0.000.0 %

%0.0kW

kVAr


Warning Shutdown Electrical Trip

Engine

24

The second page of the Alarms tab shows the event log with a list of events including normal operation events and alarm notifications with the most recent events at the top of the list. All indexed events include the date and time of the event, hours of runtime on the engine when it occurred, along with the event name or alarm type and details.

To scroll down within the event log, press the Enter () button. The scroll bar will change to blue, signifying it is active. Press the ▲ or buttons to scroll up or down in the event log. When finished, press the Enter () button again.

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 (open/closed status) of the input and output.

SCHEDULE TAB

The Scheduler tab shows the current configuration and status of the scheduler, located below the generator summary. At the bottom of the screen, the maintenance configuration status and time remaining until an alarm, electrical trip or shutdown will occur. The lamp(s) to the left shows the configuration status of the maintenance alarm, not the alarm

Alarm TypeColor -

Background/TextGraphic

Warning Yellow/Black

Electrical Trip Purple/Black

Shutdown Red/Black

ECU Code Blue/White

Warning

Electrical Trip

Shutdown

Engine

00405

GEN

V+ -



0.0 Hz

Total GeneratorkWh+

kVAhkVArh

kWkVAkVArpf

0.0

0.00.0

0.00.00.0

0.000.0 %

%0.0kW

kVAr


Warning

ShutdownShutdown

ShutdownShutdownShutdownShutdownShutdownShutdownShutdownShutdownShutdownShutdown

This is an event index 1This is an event index 2This is an event index 3This is an event index 4This is an event index 5This is an event index 6This is an event index 7This is an event index 8This is an event index 9This is an event index 10This is an event index 11This is an event index 12This is an event index 13

1 01/01/1970 00:00:01 0:002 02/06/1970 11:45:55 0:003 01/01/1970 00:00:00 0:004 01/01/1970 00:00:00 0:005 01/01/1970 00:00:00 0:006 01/01/1970 00:00:00 0:007 01/01/1970 00:00:00 0:008 01/01/1970 00:00:00 0:009 01/01/1970 00:00:00 0:0010 01/01/1970 00:00:00 0:001112 01/01/1970 00:00:00 0:0013 01/01/1970 00:00:00 0:00

01/01/1970 00:00:00 0:00

Index Date Time Hrs Event Details

00406

GEN

V+ -



0.0 Hz

Total GeneratorkWh+

kVAhkVArh

kWkVAkVArpf

0.0

0.00.0

0.00.00.0

0.000.0 %

%0.0kW

kVAr


Digital InputsIp Description Active State Ip Description Active State

A

B

C

D

EF

H

I

J

G

K

25

condition.

STATUS TAB

The Status tab contains the status and configuration of the controller, firmware and data connections.

GENERATOR MONITORING

Generator information is displayed on both the Generator operator screen and Generator tab within the maintenance screens. For more information, refer to “Operator Screens” on page 21 and “Maintenance Screens” on page 23.

ENGINE MONITORING

Engine information is displayed on both the Engine operator screen and Engine tab within the maintenance screens. For more information, refer to “Operator Screens” on page 21 and “Maintenance Screens” on page 23.

DIESEL EXHAUST FILTER MONITORING

This unit is equipped with a Diesel Particulate Filter (DPF) to meet current EPA emissions standards. This section gives an explanation of the indicators that are displayed on the DPF Status page of the Engine tab.

To access the DPF Status page, press any direction arrow (▲, ►, ▼, ◄) to enter the maintenance screens, and then while on the Engine tab, press the ▼ button to toggle through the pages until the DPF Status page appears. There are four areas on the DPF Status page that communicate various information to the operator. The areas and the indicators that appear in those areas are explained here:

00407

GEN

V+ -



0.0 Hz

Total GeneratorkWh+

kVAhkVArh

kWkVAkVArpf

0.0

0.00.0

0.00.00.0

0.000.0 %

%0.0kW

kVAr


WarningWarningWarning

ActionDescriptionAlarm Hours Date TimeMaintenance

Scheduler Enabled to run Reserved ReservedEvent Week Day Start Stop Duration Event Week Day Start Stop Duration

250 hr Maint. - Refer to Manual500 hr Maint. - Refer to Manual3000 hr Maint. - Refer to Manual

1 250:002 500:003 3000:00

All Monday 00:00 00:00 0:00

All Monday 00:00 00:00 0:00All Monday 00:00 00:00 0:00

All Monday 00:00 00:00 0:00All Monday 00:00 00:00 0:00All Monday 00:00 00:00 0:00All Monday 00:00 00:00 0:00All Monday 00:00 00:00 0:00

910111213141516

All Monday 00:00 00:00 0:00All Monday 00:00 00:00 0:00All Monday 00:00 00:00 0:00All Monday 00:00 00:00 0:00All Monday 00:00 00:00 0:00All Monday 00:00 00:00 0:00All Monday 00:00 00:00 0:00All Monday 00:00 00:00 0:00

12345678

00408

GEN

V+ -



0.0 Hz

Total GeneratorkWh+

kVAhkVArh

kWkVAkVArpf

0.0

0.00.0

0.00.00.0

0.000.0 %

%0.0kW

kVAr


- DCD- DSR- DTR- RTS- CTS

Model

Link Quality 100%

ApplicationUSB IDSupervisor State:Engine State:Load State:

Protections:LoggingLog Dest:Log Mode:USB drive:Host IP:Host Port:

Slave IP:Slave Port:

Total memLog mem freeLog Time:

BootloaderAnalogueEngine:

ModelApplicationUSB IDBootloaderEthernet

26

• HEST Lamp (High Exhaust System Temperature): This area will display the Regeneration Underway indicator above the words “HEST Lamp - Solid” when the unit is in the process of diesel exhaust filter regeneration. During the regeneration process, the exhaust temperature will be very high.

• DPF Lamp: This area will display the Regeneration indicator above the words “DPF Lamp - Solid” when auto exhaust filter cleaning is enabled. When the unit is being operated with auto exhaust filter cleaning disabled, the indicator will begin to flash above the words “DPF Lamp -Flashing” if the soot load level goes above 80%.

• 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.

For more information on the operation of auto exhaust filter regeneration and service regeneration, refer to “Exhaust Filter Cleaning Operations” on page 38.

POWER ZONE™ CONTROLLER INFORMATION DISPLAYS, FUNCTIONS, AND RESET

The Power Zone™ controller 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 main display 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 Enter () button.

00409

DPF Status

HEST Lamp - Solid DPF Lamp

DPF Inhib Alarm

Engine Generator Alarms I/O Schedule Status6/6

00410

DPF Status

HEST Lamp DPF Lamp - Solid

DPF Inhib Alarm


DPF Status

HEST Lamp DPF Lamp - Flashing

DPF Inhib Alarm


00411

DPF Status

HEST Lamp DPF Lamp

DPF Inhib - Solid Alarm


00412

DPF Status

HEST Lamp DPF Lamp

DPF Inhib Alarm - Solid


27

GENERATOR OUTPUT CONNECTION LUGS

The unit is equipped with connection lugs, located on the lower portion of the control box behind the lug box door. 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.

WARNINGIt is HIGHLY RECOMMENDED that only a trained and licensed electrician perform any wiring and related connections to the generator. Installation should be in compliance with the National Electrical Code (NEC), state and local regulations. Failure to follow proper installation requirements may result in equipment or property damage, per-

sonal injury, or death.

WARNINGBefore any connections are made to the generator, make sure that the main circuit breaker and the Control Power switch are in the OFF (O) position. Potentially lethal

voltages may be present at the generator connection lugs.

DANGERIMPROPER OR INCORRECT CONNECTIONS TO A BUILDING’S ELECTRICAL SYSTEM CAN CAUSE POTENTIALLY LETHAL VOLTAGES TO BACKFEED INTO 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 opening in the bottom of the box. DO NOT make any connections directly to the lugs without routing the cables through the slot. Use a hex-wrench to tighten the cable connections. The connection lug door is equipped with safety interlock switches that will trip the main circuit breaker and disable the voltage regulator, if the door is opened while the unit is operating.

WARNINGNever attempt to disable or modify the lug door safety switches. Equipment damage, personal injury or death

may result.

A ground connection is located next to the connection lugs. The unit MUST be connected to a good earthen ground for proper operating safety. The generator neutral is bonded to ground when it is shipped from the factory. The bonding plate will need to be removed when the generator is used as a standby power source. INSTALLATION SHOULD BE IN COMPLIANCE WITH THE NATIONAL ELECTRICAL CODE (NEC), STATE AND LOCAL REGULATIONS.

GENERATOR CAM LOCK CONNECTION(S) OPTION

The unit may be equipped with cam lock connections located below the receptacles. These receptacles provide connection points for the attachment of external loads to the generator. A decal below the cam lock connections details the proper connections for selected voltages.

WARNINGIt is HIGHLY RECOMMENDED that only a trained and licensed electrician perform any wiring and related connections to the generator. Installation should be in compliance with the National Electrical Code (NEC), state and local regulations. Failure to follow proper installation requirements may result in equipment or property damage, per-

sonal injury or death.

RUN CABLES THROUGHOPENING IN BOTTOM

OF LUG BOX

00450

28

WARNINGBefore any connections are made to the generator, make sure that the main circuit breaker and the Control Power switch are in the OFF (O) position and that the negative (-) battery cable is disconnected. Potentially lethal voltages may be present at the

generator connection lugs.

DANGERIMPROPER OR INCORRECT CONNECTIONS TO A BUILDING’S ELECTRICAL SYSTEM CAN CAUSE POTENTIALLY LETHAL VOLTAGE TO BACKFEED INTO 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 should be made by plugging power cables equipped with series 16 taper nose 400A/600V cam lock plugs into the cam lock receptacles. Secure the connection by rotating the plug a 1/2 turn to the right.

WARNINGNEVER attempt to disable or modify the lug door safety switches. Equipment damage,

personal injury or death may result.

A ground connection is located on the far right of the cam lock panel. The unit MUST be connected to a good earthen ground for proper operating safety. The generator neutral is bonded to ground when it is shipped from the factory. The bonding plate will need to be removed when the generator is used as a standby power source. INSTALLATION SHOULD BE IN COMPLIANCE WITH THE NATIONAL ELECTRICAL CODE (NEC), STATE AND LOCAL REGULATIONS.

WARNINGSome units are equipped with two sets of cam lock connections. Make sure all connections to the cam lock receptacles are made to one side only, below each

corresponding breaker. i.e. DO NOT attach L1, L2 and L3 to the left side and Neutral and Ground to the right side.

VOLTAGE SELECTOR SWITCH

The voltage selector switch 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.

NEVER change the voltage selector switch while the engine is running or the controller is on. If the engine is running or starts while the setting is changed, severe arcing will occur

causing damage to the switch and generator windings.

The voltage selector switch is equipped with a lockout mechanism. Once the proper voltage has been selected, insert a padlock through the lockout hole(s). By locking the handle in place, unauthorized changing of the voltage

L1L2L3

N (Neutral)G (Ground)

BlackRedBlueWhiteGreen

CAM LOCK PANEL

00451

29

setting is prevented.

VOLTAGES AT RECEPTACLES

277/480V 3-PHASE

Switch styles vary by model.

L1-L2 = 480V L1-N = 277V N = L2-L3 = 480V L2-N = 277VL3-L1 = 480V L3-N = 277V

277/480V

120/208V

RECEPTACLE L-L L-NGFCI - 139VGFCI w/Buck - 120VTwist-locks 240V 139V

00083



120/208V 3-PHASE



277/480V

120/208V

120/240V

00085



120/240V 3-PHASE


RECEPTACLE L-L L-NGFCI - 120VGFCI w/Buck - 120VTwist-locks 120V 0/120V

120/240V 3PH

277/480V

120/208V

120/240V 1PH

4 Position Voltage Selector Switch Option00086

L1-L2 = - L1-N = 120V N = L2-L3 = - L2-N = -L3-L1 = 240V L3-N = 120V


120/240V 1-PHASE



120/208V

120/240V

00087

= Not recommended for normal use.

30

PRESTART CHECKLIST

Before starting the unit, carefully read the prestart checklist. Make sure that all of the items are checked before trying to start the unit. This checklist applies to both manual and remote starting of the unit.

Read and understand ALL safety sections at the beginning of this manual. Check the Control Power switch is in the OFF (O) position. Check all the circuit breakers are switched to the OFF (O) position. Verify the unit is properly grounded to a good earthen ground. Installation should be in compliance with

the National Electrical Code (NEC), state and local regulations. Inspect all electrical cords; repair or replace any that are cut, worn, or bare. Verify all electrical connections at the connection lugs are tight and wired correctly. Verify the voltage selector switch is set to the desired voltage and locked. Check the unit is level. Thoroughly check for any water inside, on, or near the generator. Dry the unit before starting. Check oil, coolant, and fuel levels. For more information, refer to “General Maintenance” on page 40. Check the engine fan belt tension and condition. Check the engine fan belt guard. Check the engine exhaust system for loose or rusted components. Check the radiator and surrounding shroud for debris. Check to make sure none of the generator covers are loose or missing. Verify all maintenance procedures are up to date. For more information, refer to “General

Maintenance” on page 40. Verify the engine battery connections are secure. Check that the battery disconnect switch is on, if equipped. Verify the emergency stop switch is pulled out.

ENGINE BREAK-IN REQUIREMENTS

Note: During the first 20 hours of operation, avoid long periods of no load or sustained maximum load operation. If the generator is to run for longer than five minutes without a load, shut the generator down.

John Deere engines are supplied with engine break-in oil from the factory. Extra care during the first 100 hours of engine operation will result in better performance and longer engine life. DO NOT exceed 100 hours of operation with the break-in oil. Operate the engine at heavy loads (60-90% of maximum) as much as possible. If the engine has spent significant time at idle, constant speed(s), and/or light load, or if makeup oil is required, a longer break in period may be needed. Refer to the engine operator’s manual for a full description of necessary procedures on the addition of break-in oil and extension of the break-in period. For more information on regular maintenance intervals, refer to “Basic Maintenance Schedule - John Deere Engine” on page 41.

EMERGENCY STOP SWITCH

The unit is equipped with one emergency stop switch. For location of the emergency stop switch, refer to “Component Locations” on page 15. The red switch is clearly labeled “EMERGENCY STOP.” The switch can be accessed and activated with all doors closed and locked.

Activate the emergency stop switch by pushing the red button in until it locks down. This will trip the main circuit breaker which will open the contact, disconnecting the load to the connection lugs. This will also open the fuel circuit, shutting down the engine. The emergency stop fault will be displayed on the control panel.

The switch will remain closed until it is pulled out.

Use the emergency stop switch only when the unit must be shut down immediately. For any

STOP

E

MERGENCY

00230

31

other shut down, refer to “Shutting Down the Unit” on page 38.

MANUAL STARTING OF THE UNIT

All units equipped with the Power Zone™ controller will initially start up in Stop mode. Use the following procedure to start the generator in Manual mode:

1. Move the Control Power switch to the ON (I) position.

DANGERCARBON MONOXIDE: USING A GENERATOR INDOORS CAN KILL YOU IN MINUTES.

2. The LCD window 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 Stop mode as

indicated at the top of the screen. Press the Auto/Manual Mode ( ) button to enter Manual mode.

Note: The controller can be started from any screen when it is in Manual mode.

4. Pressing the green Engine Start (I) button on the controller will initiate the startup procedure and start the engine, provided there are no engine faults preventing the unit from starting.

Note: It may take a few seconds for the engine to run smoothly and reach its governed operating speed. During this time, the screen will show a voltage different from that set with the voltage selector switch.

5. 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 “Manual Mode - Crank Rest” at the top of the screen. The engine will make two more attempts to start for a total of three crank cycles.

00414

82%

Image File Transer...

TM

00415

Stop Mode

3 PHASEVolts

Amps

0

0

0.0 kW

%

0

10

100 110

20

30

4050

6070

8090

Time to Empty15 hr

Full

3/4

1/2

1/4

Empty

74

%

GEN

V+ -

32

6. Should the engine not start and run within three starting cycles, the LCD window will show the “Fail to Start” alarm. The starting sequence may be repeated after the starter has had a minimum of two minutes to cool. Pressing the Enter () button will clear the alarm and reset the controller.

Note: The engine controller may skip the preheat engine steps on some of the larger models.

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. The output voltage can be fine adjusted by using the Voltage Adjust screen as described on page 38.

10. Check that the frequency (Hz) is correct on the Generator screen. With no loads connected to the generator, the frequency should read approximately 60 Hz, depending on the type of engine governing used.

11. If all wiring connections have been made correctly, switch the main circuit breaker to the ON (I) position and then add any loads attached to the receptacles by switching the respective circuit breaker to the ON (I) position. You will notice a slight change in engine sound when a load is applied to the unit.

AUTO (REMOTE) STARTING OF THE UNIT

Auto Mode is used when the unit is started from a location other than the control panel 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 unit in the Auto mode, review the “Prestart Checklist” on page 31 and “Manual Starting of the Unit” on page 32. Also follow all safety warnings and information on isolating the generator with a transfer switch if the unit is to be used as a standby power supply. Refer to “Prestart Checklist” on page 31. Then continue with the steps described below:

1. Perform a manual start of the unit at least once to verify that the engine is operating correctly.2. If a check of the remote start circuit is desired, remove the wires from the remote start terminal block.

Press the Auto/Manual Mode ( ) button, the LCD window should show “Auto Mode” at the top of the screen. Attach a jumper wire (minimum 16 gauge) across the two terminals on the remote start terminal block. This applies a ground to the Power Zone™ Controller to close the starting circuit contacts. 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 the unit is in Auto mode. The LCD window should show “Auto Mode” at the top of the screen.5. Close the main circuit breaker (set to the ON (I) position).6. Secure the unit by closing and locking all access doors.7. The unit is now ready for remote starting.

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 protention (U/F), droop, stability, voltage, and trim. The voltage regulator on the unit is adjusted before shipment from the factory. Contact Magnum Power Products LLC for additional information before attempting to adjust the voltage regulator.

Note: For units equipped with a Marathon DVR2000E+ digital voltage regulator, please refer to the Marathon operating manual provided with the unit.

33

DERATING FOR ALTITUDE

All units are subject to derating for altitude and temperature; this will reduce the available power for operating tools and accessories connected to the receptacles. Typical reductions in performance are 2-4% for every 1000 ft (305 m) of elevation and 1% per 10ºF (5.6ºC) increase in ambient air temperature over 72ºF (22ºC).

WET STACKING

The unit is powered by a diesel engine. Diesel engines are susceptible to wet stacking if lightly loaded. Wet stacking occurs when an engine is run at less than 30% of its full load capacity, causing unburned fuel to accumulate in the exhaust system. Wet stacking can be detected by continuous black exhaust when the unit is under a constant load. It can also cause fouling of injectors and buildup on engine valves. Diesel engines operate properly when applied loads are between 30% and 100% capacity. Appropriate generator sizing is determined by the anticipated load. If the unit is in a wet stack condition, load the unit heavily for five hours or until the exhaust is clear.

Wet stacking in the exhaust system is less likely to occur in iT4-certified engines because of regeneration of the Diesel Particulate Filter (DPF). During the regeneration process, exhaust temperatures are increased to burn off accumulated particulate, and in the process also removes any un-burned diesel fuel or engine oil in the exhaust system. Wet stacking may still be present in the engine due to low cylinder temperatures.

Note: If the unit has a 15% or less load for 10 minutes, “Wet Stacking Alarm” will pop up. The unit will still run but the controller will be inaccessible. The alarm needs to be acknowledged in order to allow the controller to be accessible again by pressing the Alarm Mute button.

CONTROL PANEL RECEPTACLES

The generator is equipped with five receptacles. The large receptacles are 240/120VAC twist-lock recep-tacles rated at 50A each. The smaller duplex recep-tacles are 120VAC 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 receptacle. Each breaker is sized to the maximum rating of the corresponding recepta-cle.

Power to the receptacles is available any time the generator is running, EVEN IF THE MAIN CIRCUIT BREAKER IS IN THE

OFF (O) POSITION. MAKE SURE THAT ANY EQUIPMENT

CONNECTED TO THE RECEPTACLES IS TURNED OFF BEFORE TURNING THE

BREAKERS ON. Make sure that the voltage selector switch is in the proper position and that the output voltage is correct for the equipment that is connected to

the receptacles. Improper voltage may cause equipment damage or

malfunction.

120V GFCIReceptacles

50A Circuit Breakers

20A Circuit Breakers

120/240VTwist-Lock

Receptacles

00453

34

Note: When the voltage selector switch is in position for 480/277V 3Ø, voltage at the two GFCI receptacles is 139 volts and the voltage at the three twist-lock receptacles is 240/139 volts. Magnum Power Products LLC does not recommend using the receptacles in the 480V position without a buck transformer. When the voltage selector switch is in position for 208/120V 3Ø, voltage at the three twist-lock receptacles and the two GFCI receptacles is 208/120 volts.

MAIN CIRCUIT BREAKER

The main circuit breaker is located on the main control panel. When the breaker is in the OFF (O) position, power is interrupted between the connection lugs, the optional cam lock receptacles, and the generator. Once the connections have been made to the connection lugs or the optional cam lock receptacles, and the generator has been started and allowed to reach normal operating temperature, the breaker may be switched to the ON (I) position.

The main circuit breaker will be tripped, disconnecting power to the connection lugs and the optional cam lock receptacles if any of the following items occur while the unit is running:

1. Overload of the generator circuits to the connection lugs or the optional cam lock receptacles (208/120V only).

2. The door covering the connection lugs or the optional cam lock receptacles is opened.3. If the emergency stop switch is activated.

Make sure any problems that cause the main circuit breaker to trip are corrected before returning the switch to the ON (I) position.

WARNINGThe main circuit breaker interrupts power to the connection lugs and the optional

cam lock receptacles only. The control panel receptacles have power even if the main circuit breaker is in the OFF (O) position. To disconnect power to these receptacles,

use the individual circuit breakers located near each receptacle.

REMOTE START TERMINAL BLOCK

The remote start terminal block provides a connection for installation of a remote start switch which will allow the unit to be started by a remote dry-contact closure switch. For location of the remote start terminal block, refer to “Main Control Panel Features” on page 16.

Before entering Auto mode, verify that the contacts on any remote switch linked to the unit are OPEN. If the contacts on a remote switch are closed, the engine will crank and start when Auto mode is entered. Attach the switch leads to the two unused terminals on the unit’s remote start terminal block. For additional information, refer to “Auto (Remote) Starting of the Unit” on page 33.

TRANSFER SWITCH

The generator neutral is bonded to ground when shipped from the factory. The bonding plate will need to be removed when the generator is used as a standby power supply.

Installation should be in compliance with the National Electrical Code (NEC), state and local regulations.

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.

On/I On/I

Off/O Off/O

00452

Remote StartSwitch Terminals 00231

35

DANGERFAILURE TO ISOLATE THE GENERATOR FROM THE NORMAL POWER UTILITY CAN CAUSE POTENTIALLY LETHAL VOLTAGE TO BACKFEED INTO THE UTILITY LINES. THIS MAY RESULT IN INJURY OR ELECTROCUTION OF UTILITY WORKERS NEARBY. MAKE SURE THE GENERATOR IS ISOLATED BY A TRANSFER SWITCH FROM ANY LOCAL UTILITY LINES. THIS ALSO APPLIES IF THE GENERATOR IS BEING USED

AS A BACKUP TO SOME OTHER TYPE OF POWER SUPPLY.

Installation of a transfer switch or other type of remote starting device is the responsibility of the generator user. Installation of such devices must be performed by following all directions supplied by the manufacturer of the switch. If attaching the generator to a power supply normally serviced by a utility company, notify the utility company and check state and local regulations. Familiarize yourself with all instructions and warning labels supplied with the switch.

WARNINGONLY a licensed electrician should perform wiring or related connections to the generator. Installation should be in compliance with the National Electrical Code

(NEC), state and local regulations. Failure to follow these procedures could result in property damage, personal injury or death. Before any connections are attempted, make sure the main circuit breaker and the Control Power switch are in the OFF (O) position and that the negative (-) battery cable has been disconnected from the engine

starting battery.

When using the generator as a standby or substitute power supply, make sure the output voltage and phase rotation of the generator match those of the local power utility. Improper

voltage or phase rotation may cause equipment damage or malfunction.

AUTO EXERCISE TIMER

The Power Zone™ controller is capable of starting and stopping the unit automatically, based on a programmable schedule.

Units installed in a standby application should be exercised regularly to maintain operating condition and to ensure responsiveness in an emergency situation. Use the following procedures to operate the unit in Auto mode:

ACCESSING THE CONFIGURATION MENU

1. With the unit stopped, press ▲, ►, ▼, or ◄ to navigate to the maintenance screens from any of the operator screens.

IncomingUtilityPower

UtilityMeter Transfer

Switch

MainDistribution Panel

(Utility Power)

EmergencyDistribution Panel(Generator Power)

Power FromGenerator

WHITE = IncomingUtility PowerGRAY = Normal UtilityPower CircuitBLACK = EmergencyGenerator Power Circuit

00206

36

2. While on any maintenance screen, press and O simultaneously. The controller will display the Configuration menu.

3. To save any changes and exit the Configuration menu, press and hold for five seconds. To cancel any changes and return to the maintenance screen, press and hold O for five seconds.

SET THE CONTROLLER CLOCK

The schedule runs based off the time set in the controller clock. Use the following procedure to set the controller clock BEFORE setting the schedule:

1. Navigate to the Maintenance group and press ► to access it.

2. Press ► to select the Time section.

3. Set the time and date to the correct local time.

SET THE SCHEDULE

1. Access the Scheduler group by pressing the ► button.

Note: The Scheduler group is made up of the Scheduler Options and Scheduler Setup sections. Each section can be accessed and exited using the ► and ◄ buttons.

2. Access the Scheduler Options section. Within this section, the scheduler can be enabled, run mode selected, and load mode selected.

3. Access the Scheduler Setup section. Within this section, each schedule entry can be modified by pressing the button to select the item and the ▲ and ▼ buttons to define them.

Note: The controller must be in Auto mode to run at the programmed time. Use a trickle or solar battery charger to prevent the controller from draining the battery while in Auto mode.

SET THE UNIT TO AUTO MODE

1. From any operator or maintenance screen, press and hold the Auto/Manual Mode button for five seconds, or until Auto mode is displayed at the top of the screen.

Note: If any of the scheduled time slots are currently active, the controller will begin the starting sequence and start the unit provided there are no shutdown conditions present.

Item Values

Enable Yes/No

Run Mode Monthly/Weekly

Load Idle, In Island, On Load, Off Load

Item Values

Schedule Entry 1-16

Start Time 00:00-23:59

Duration 00:00-99:59

Day Monday-Sunday

Week (of month) First, Second, Third, Fourth

37

FINE VOLTAGE ADJUSTMENT

Adjustment of the output voltage from the generator is necessary to provide the correct voltage to the end of the power line. Voltage adjustment can be carried out at any time on the Voltage Adjust screen.

1. With the unit running, press .

2. Press . The voltages displayed will begin flashing.

3. Use ▲ and ▼ to adjust the voltage.

4. Press to confirm the new voltage. The voltages displayed will stop flashing.

SHUTTING DOWN THE UNIT

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 the OFF (O) position).

2. Let the engine run for approximately five minutes to allow it to cool down.

3. Push O. Pressing the red Engine Stop/Reset (O) button will result in the generator going into the shutdown cycle and starting a 15 second shutdown timer called stopping. If the unit does not shut down within 15 seconds, a stop fail alarm will be displayed on the LCD window.

4. After the unit shuts down, move the Control Power switch to the OFF (O) position.

Note: For extended storage time, disconnect the battery. Refer to the engine operator’s manual for extended storage requirements.

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 involve-ment. In the event there are conditions requiring the operation of the unit with the auto exhaust filter cleaning disabled, the operator may be required to perform procedures to enable or disable the auto exhaust filter cleaning. The operator may also be required to perform a manual regeneration. The following procedures describe how to perform these functions.

00396

Manual Mode

GEN

V+ -

Voltage Adjust

- Press , voltage will begin flashing- Use and arrows to adjust voltage- Press to confirm new voltage. Numbers will stop flashing

V L-N Average

L-L AverageV

480277

V+ -

38

WARNINGThe area above and surrounding the exhaust system during an auto or manual exhaust filter cleaning should be clear of any people and objects. Exhaust gases and compo-

nents can reach temperatures hot enough to ignite and melt common materials.

Note: Always park the unit in a safe location for elevated exhaust temperatures and check for adequate fuel level before beginning the exhaust filter cleaning process. The cleaning cycle can take an extended period of time (approximately 45 minutes). Cleaning is complete when the Regeneration indicator remains off.

DISABLE AUTOMATIC (AUTO) EXHAUST FILTER CLEANING

The auto exhaust filter cleaning feature should always be enabled unless doing so would cause an unsafe working environment. In the event that an unsafe working environment would occur, use the following procedure to disable the auto exhaust filter cleaning feature:

1. Open the control door and locate the switch labeled “EXHAUST FILTER CLEANING.”2. Move the switch into the DISABLED (O) position.3. Enter the DPF Status screen and verify the Disabled Regeneration indicator appears above the words

“DPF Inhib - Solid.” For information regarding the DPF Status screen and indicators, refer to “Diesel Exhaust Filter Monitoring” on page 26.

Disabling Auto Exhaust Filter Cleaning is not recommended for any situation unless it is safety related or if the fuel tank lacks the required fuel to complete the cleaning process.

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 “EXHAUST FILTER CLEANING.”2. Move and hold the switch into the ON / FORCED (I) position for five seconds.3. Enter the DPF Status screen and verify the Regeneration indicator appears above the words “DPF Lamp

- Solid.” For information regarding the DPF Status screen and indicators, refer to “Diesel Exhaust Filter Monitoring” on page 26.

ENABLE EXHAUST FILTER CLEANING

If the environment no longer requires the function to be disabled and there are no alarms present on the DPF Status screen, the auto exhaust filter cleaning function should be enabled. Use the following procedure to enable the auto exhaust filter cleaning feature:

1. Open the control door and locate the switch labeled “EXHAUST FILTER CLEANING.”2. Move the switch into the ON / AUTO (I/O) position.3. Enter the DPF Status screen and verify the Regeneration indicator appears above the words “DPF Lamp

- Solid.” For information regarding the DPF Status screen and indicators, refer to “Diesel Exhaust Filter Monitoring” on page 26.

TOWING THE UNIT

1. Use the jack to raise or lower the trailer onto the hitch of the towing vehicle. Lock the hitch coupling and attach the safety chains or cables to the vehicle. Raise the jack foot completely.

2. Connect any trailer wiring to the tow vehicle. Check for proper operation of the directional and brake lights.

3. Make sure all doors are properly latched.

39

4. Check for proper inflation of the trailer tires. For maximum tire pressures, refer to Specifications beginning on page 10.

5. Check the wheel lugs. Tighten or replace any that are loose or missing. If a tire has been removed for axle service 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).

Note: 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). Recom-mended off-road towing speed is not to exceed 10 mph (16 km/h) or less, depending on terrain.

LIFTING THE UNIT

A central lift point is located on the top of the unit. The central lift point is connected to a lift structure inside the unit. Attach a sling or hook directly to the central lift point only if the devices are in good condition and the equip-ment being used to raise the unit has sufficient capacity. For approximate weights, refer to Specifications begin-ning on page 10. Always remain aware of others around you when moving or lifting the unit. Keep the doors closed and locked.

DAILY WALK AROUND INSPECTION

Look for conditions that could hinder performance or safety, such as (but not limited to) oil/coolant/fuel leakage, blocked vents, loose/missing hardware, and electrical connections.

Visually inspect the fan belt for cracks, fraying, stretching, and verify the belt is properly seated in the pulley grooves. Replace the belt according to the manufacturer’s recommendations.

Note: At the 500 hour/12 month service interval, it is recommended that the belt be removed and checked for wear. While the belt is removed, inspect pulleys and bearings. Rotate and feel for hard turning or unusual sounds. If pulleys or bearings need replacement, contact the engine manuafacturer.

Failure to perform a daily inspection may result in serious damage to the prime mover.

GENERAL MAINTENANCE

Poorly maintained equipment can become a safety hazard. In order for the equipment to operate safely and properly over a long period of time, periodic maintenance and occasional repairs are necessary. NEVER perform routine service (oil/filter changes, cleaning, etc.) unless all electrical components are shut off. Before servicing the unit, always follow the instructions listed below.

• Verify the Control Power switch is turned to the OFF (O) position.• Verify the circuit breakers are open, the OFF (O) position.• Activate (push in) the emergency stop switch.• Disconnect the negative (-) terminal on the battery.• Attach a “Do Not Start” sign to the control panel. This will notify everyone that the unit is being serviced and

will reduce the chance of someone inadvertently trying to start the unit.• Never wash the unit with a high pressure hose or with any kind of power washer.

52

341

00204

Central Lift Point

00419

40

• 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.

• Inspect condition of electrical cords. DO NOT use the unit if insulation is cut or worn through.• Check the condition of the air filter by viewing the level of the vacuum draw on the filter minder gauge.

Replace the air filter when the yellow center bar reaches the red section on the gauge (20 in. H2O).

• Check the wheel lugs. Refer to “Towing The Unit” on page 39.• Check the coolant level daily. Refer to the engine operator’s manual for coolant recommendations and proper

mixture.○ Coolant is checked visually by inspecting the level in coolant overflow jug located near the radiator.○ Normal operating level is anywhere between the full and add markings on the overflow jug known as normal range.○ WHEN ENGINE IS STOPPED AND COMPLETELY COOL, coolant may be added directly to the coolant overflow jug.

• Check the oil level daily. Refer to the engine operator’s manual for the proper grade of oil, including special operating conditions such as a change in season or climate.○ DO NOT start the unit if the engine oil level is below the add mark on the dipstick.○ Normal operating level is anywhere in the cross-hatch pattern between the full and add markings on the dipstick.○ Add oil to the engine only if oil level is below the add mark on the bottom of the cross-hatch pattern on the dipstick. DO NOT OVERFILL crankcase.

• Check the fuel level.• If the unit is connected to a remote start or transfer switch, make sure the remote switch is also off and tagged.

Note: If the engine was run out of fuel or the fuel tank was drained, it may be necessary to bleed the fuel lines. Refer to the engine operator’s manual supplied with the unit.

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. For additional or replacement copies of the engine operator’s manual, contact an authorized dealer in your area.

Item Daily250Hrs.

500Hrs./12 Months

3000Hrs./ 36 Months

As Required

Check Oil Level

Check Coolant Level

Check Fuel Level

Check Tire Pressure

Check All Electrical Connections

Inspect Radiator Fins For Debris, Clean As Required

Check Fuel Filter/Water Separator Bowl

Check Air Cleaner Dust Valve Restriction Indicator Gauge *

Perform Visual Walkaround Inspection

Check Oil Vapor Recirculation System/Non-Return Valve

Change Engine Oil and Replace Oil Filter **

Replace Oil Vapor Recirculation Filter

Service Battery

41

* 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 500 hours. If not using John Deere Plus 50 II engine oil, the interval must be decreased to every 250 hours.

RESETTING THE MAINTENANCE ALARMS

The Power Zone™ controller will display a warning message when the unit is due for maintenance or service. The maintenance or service intervals are set at 250, 500, and 3000 hours of engine running time. Once the unit has been serviced, the appropriate maintenance alarm reminder needs to be reset. The following procedure demonstrates how to reset the maintenance alarms:

1. With the unit shut down, move the Control Power switch to the ON (I) position. After initialization, the controller will toggle automatically to the Home screen.

2. Press ▲, ►, ▼, or ◄ to enter the maintenance screens.

3. Press and O simultaneously. The next screen will display the Configuration menu.

4. Press to move the cursor (blue highlighted text) down to the Maintenance group.

5. Press ► to access the sections. Press to highlight the Maintenance section.

6. Press ► to access the parameters and highlight the maintenance alarm that needs to be reset.

7. Press to select the editable parameters. The cursor will highlight “Not Reset” under the selected maintenance alarm. Press to highlight “Reset”.

8. Press to reset the selected maintenance alarm.

Note: If the selected maintenance alarm does not need to be reset, press to highlight “Not Reset” and press to return to the parameters section.

1. To perform additional maintenance alarm resets, repeat steps 6-8.2. To save changes, press and hold for five seconds. To discard changes made, press and hold O for

five seconds.

Replace Fuel Filter Elements

Check Engine Mounts

Check Air Intake Hoses, Connections, and System

Check Engine Electrical Ground Connection

Check Automatic Belt Tensioner and Belt Wear

Check Cooling System

Lubricate Leveling Jack(s)

Check Generator Drive Plate Torque (refer to page 43)

Test Thermostats

Replace Air Cleaner Elements

Replace Alternator and Fan Belts

Check Fuses

Add Coolant

Check Electrical Wiring and Connections

Item Daily250Hrs.

500Hrs./12 Months

3000Hrs./ 36 Months

As Required

42

BELT TENSIONERS

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.

EXHAUST FILTER SERVICE REQUIREMENTS

The exhaust filter system 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 3,000 or 4,500 hours, based on engine power and operating conditions. Actual service should take place when the indicator light appears on the Power Zone™ controller. The DPF should be cleaned or replaced by an authorized service provider only. The removal of DPF ash must be done by removing the DPF from the unit and placing it into specialized equipment.

CAUTIONDo not remove ash by using water or other chemicals. Removing ash by these methods

may cause equipment damage and create unsafe operating conditions.

CAUTIONOnly a qualified service provider should remove, handle and dispose of DPF ash. These

materials may be considered hazardous under federal, state and local regulations, and must be handled and disposed of properly.

To avoid unnecessary buildup of diesel particulates or soot in the exhaust filter system:

1. Utilize the Automatic Exhaust Filter Cleaning mode.2. Avoid unnecessary idling.3. Use proper engine oil. Refer to the engine operator’s manual.4. Use only ultra low sulfur diesel fuel. Refer to the engine operator’s manual.

ECU OVERRIDE SWITCH

The ECU override switch is located inside the control box. This toggle switch powers up the ECU without having to start the engine. Use the ECU override switch to turn the ECU off. If the unit needs to be shut down immediately, use the emergency stop switch. Refer to “Emergency Stop Switch” on page 31 for additional information.

DO NOT start the engine with the ECU override switch on. Doing so will damage the ECU.

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 41.

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-lbs (Nm)

MMG130D 36 (49)

00420

43

4. Reinstall the generator fan guard. Reconnect the battery.

JACK MAINTENANCE

The following procedures should be performed at least annually.

SIDE-WIND MODELS

• The internal gearing and bushings of the jack must be kept lubricated. Apply a small amount of automotive grease to the internal gearing by removing the jack cover, or if equipped, use a needle nose applicator or standard grease gun on the lubrication point found on the side of the jack near the crank. Rotate the jack handle to distribute the grease evenly.

• A lightweight oil must be applied to the handle unit at both sides of the tube.• If equipped, the axle bolt and nut assembly of the caster wheel must also be lubricated with the same

lightweight oil.

TOP-WIND MODELS

• Apply a lightweight oil to the screw stem.

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. To lubricate the axle bearings, remove the small rubber plug on the grease cap, attach a standard grease gun fitting to the grease zerk fitting and pump grease into the fitting until new grease is visible around the nozzle of the grease gun. Use only a high quality grease made specifically for lubrication of wheel bearings. Wipe any excess grease from the hub with a clean cloth and replace the rubber plug when finished. The minimum recommended lubrication is every 12 months or 12,000 miles (19,312 km). More frequent lubrication may be required under extremely dusty or damp operating conditions.

TROUBLESHOOTING AUTOMATIC SHUTDOWN CONDITIONS

WARNINGAllow engine to cool before performing any troubleshooting procedures. Contacting

the engine when it is hot will cause severe personal injury.

LOW FUEL LEVEL SHUTDOWN

1. Check the fuel level on the LCD window. Confirm that the unit is sitting level to ensure an accurate reading.2. Check for leaks in the fuel tank. The fuel tank should not run dry under normal circumstances. The engine

controller will shut the engine down when there is five percent of fuel remaining in the tank. This is done to keep the fuel lines from running dry.

3. If the fuel level is good and no leaks are found, check the fuel level sender and the connecting wiring for damage. To check for continuity between the sender and the engine controller, remove the appropriate

MMG175 46 (63)

MMG205 47 (64)

Oil Grease

GreaseGrease

Oil Oil

OilOil

00243

44

bolts from the control panel to access the inside of the control box. Refer to the DC wiring diagram in the back of this manual for the proper path between the engine controller and the fuel level sender.

LOW OIL PRESSURE SHUTDOWN

1. Check the level of the engine oil with the dipstick. The engine controller will shut the engine down when the oil pressure is less than 20 psi (138 kPa). Add oil if required.

2. Visually inspect the engine for oil leaks.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 5 psi (34 kPa) within five seconds. 4. Check the oil pressure sender. To identify corrective action, refer to the troubleshooting section of the

engine operator’s manual provided with the unit.

LOW COOLANT LEVEL SHUTDOWN

1. Allow the engine to cool.2. Check the coolant level in the radiator. To access the radiator cap, you must remove the access panel

from the top of the enclosure directly above the radiator. Add coolant until it is 3/4 in. (1.9 cm) below the filler neck. Secure the radiator cap back into its original position.

3. Inspect coolant hoses, engine block and water pump for visible leaks.4. Check engine oil to verify no coolant has mixed with it (oil will appear milky if coolant is present). Refer

to the engine operator’s manual for additional information.

HIGH COOLANT TEMPERATURE SHUTDOWN

1. Check the coolant level in the overflow jug.2. Restart the engine and read the coolant temperature to verify a high coolant temperature shutdown.

Stop the engine immediately if the coolant temperature is 230°F (110°C) or more. 3. Allow the engine to cool. Add coolant to the overflow jug if it is low and then check the level of coolant

in the radiator. To access the radiator cap, you must remove the access panel from the top of the enclosure directly above the radiator. Add coolant until it is 3/4 in. (1.9 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 and water pump for visible leaks.6. Check the tension of the serpentine drive belt for the water pump.7. If no other problems are found, remove the load on the generator and restart the engine. Check the

coolant temperature and shut the engine down immediately if it starts to overheat. Refer to the engine operator’s manual for additional information on engine overheating.

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, refer to the engine operator’s manual for additional information on trouble-

shooting starting problems.

OVERSPEED OR UNDERSPEED SHUTDOWN

1. Disconnect all loads and restart the generator. Read the frequency (Hz) on the LCD window. With no loads on the generator, the frequency should read 60.0 Hz.

2. If the frequency is above or below 60.0 Hz, the engine speed will have to be adjusted. Refer to the engine operator’s manual for throttle adjustments on mechanically governed units and refer to the electronic governor manual for electronically controlled units. Contact John Deere with speed related issues since the engine is governed by the John Deere Electronic Engine Control Unit (ECU).

45

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. Depending on unit model, the temperature ranges vary between 170°F and 200°F (77°C and 93°C).

46

AC WIRING DIAGRAM - 3 POSITION VOLTAGE SELECTOR SWITCH - MMG130D

BREAKER240V 50A

BRN

240V 50ABREAKER

240V 50ABREAKER

BLK

BLK

BLK

BLK

BRN

5 913

6 10 14

7

8

11

12

15

16

T5

BLK

BLK

BLK

GRN/YEL

(T7)

CT-3

L2 L3S

HU

NT

L1

CT-2CT-1

BLK

GRN/YEL

GRN/YEL GRN/YEL

PAIR BLK

PAIR BLK

1

2

3

4

T4

GROUNDTO GEN FRAME

L0

MECHANICAL LUGS

GROUNDTO

FRAME

BLK

BLK50A240V

RCPT.

BLK

GFCIRECPT

120V

17 21 25

18 22 26

19

20

23

24

27

28

T9

RCPT.

240V50A

50ARCPT.

240V

BLK

BLK

BLK

T6T8T10T11T7T1T12

T2

T3

GENERATOR

F+ F-

120V20ABRKER

120V

RECPTGFCI

L3

L2

L1

L0

12V

DC

(T9)

GRN/YEL

BRKER20A120V

GND

BLKRED

15-PINAC PLUG

LT BLU LT BLU

LT BLU LT BLU LT BLU

BLK

BLK

PAIR BLK(L0)

JUMPER WIRE ONPHASE SWITCH

12-17

WIRES NOT USED IN BUCK BOOST OPTION

SEE DC WIRING DIAGRAM FOR CT CONNECTIONS


TP1

TP3

TP2

TP4

TP5

VOLTAGEPM500

A2

VR1VR2

E3F+F-

5 AMP FUSEON REGULATOR

50HZ60HZ

E2E1

A1

RDBKWTBK

REGULATOR

TO POWER ZONEAVR PINS

TO POWER ZONE PIN 40

P2P1

BNBN/WT

BN/WTBN


90473_ORG_08.29.13

47

AC WIRING DIAGRAM - 3 POSITION VOLTAGE SELECTOR SWITCH - MMG175

BREAKER240V 50A

BRN

240V 50ABREAKER

240V 50ABREAKER

BLK

BLK

BLK

BLK

BRN

5 913

6 10 14

7

8

11

12

15

16

T5

BLK

BLK

BLK

GRN/YEL

(T7)

CT-3

L2 L3S

HU

NT

L1

CT-2CT-1

BLK

GRN/YEL

GRN/YEL GRN/YEL

PAIR BLK

PAIR BLK

1

2

3

4

T4

GROUNDTO GEN FRAME

L0

MECHANICAL LUGS

GROUNDTO

FRAME

BLK

BLK50A240V

RCPT.

BLK

GFCIRECPT

120V

17 21 25

18 22 26

19

20

23

24

27

28

T9

RCPT.

240V50A

50ARCPT.

240V

BLK

BLK

BLK

T6T8T10T11T7T1T12

T2

T3

GENERATOR

F+ F-

120V20ABRKER

120V

RECPTGFCI

L3

L2

L1

L0

12V

DC

(T9)

GRN/YEL

BRKER20A120V

GND

BKRD

CONN 231 PIN

LT BLU LT BLU


BLK

BLK

PAIR BLK(L0)

(3) JUMMPER WIRES ON PHASE

SWITCH 15-20, 12-17, 10-21




TP1

TP3


VOLTAGEPM500

A2

VR1VR2

E3F+F-


50HZ60HZ

E2E1

A1

RDBKWTBK TO POWER ZONE

REGULATOR

AVR PINS

P2P1

BNBN/WT

BN/WTBN


90471_ORG_08.29.13

48

AC WIRING DIAGRAM - 3 POSITION VOLTAGE SELECTOR SWITCH - MMG205

BREAKER240V 50A

BRN

240V 50ABREAKER

240V 50ABREAKER

BLK

BLK

BLK

BLK

BRN

BLK

BLK

BLK

GRN/YEL

(T7)

CT-3

L2 L3S

HU

NT

L1

CT-2CT-1

BLK

GRN/YEL

GRN/YEL GRN/YEL

PAIR BLK

PAIR BLK

GROUNDTO GEN FRAME

L0

MECHANICAL LUGS

BLK

BLK50A240V

RCPT.

BLK

GFCIRECPT

120V

RCPT.

240V50A

50ARCPT.

240V

BLK

BLK

BLK

120V20ABRKER

120V

RECPTGFCI

L3

L2

L1

L0

12V

DC

(T9)

GRN/YEL

BRKER20A120V

GND

BLKRED

31-PIN

LT BLU LT BLU


BLK

BLK

PAIR BLK(L0)




T5

T4

GROUNDTO

FRAME

7

T9

T6

T8

T10

T11

T7

T1

T12

GENERATOR

F+ F-

(3) JUMMPERS ON PHASE SWITCH 7-43,

30-43, 30-37

T2

T33

1117

10

216

20

24

43

34

30

37

40

48

5554

50

1 3 5

642

VOLTAGEPM500

A2

VR1VR2

E3F+F-


50HZ60HZ

E2E1

A1

BN/WTBN

RDBKWTBK

BNP2P1 BN/WT

TO POWER ZONEAVR PINS

REGULATOR


TO POWER ZONE PIN 39CONN 2

2

3

90469_ORG_08.29.13

49

AC WIRING DIAGRAM - 4-POS. VOLT. SELECTOR SWITCH OPTION - MMG130D, MMG175

BR

N

GR

N/Y

EL

10G

A

(T7)

CT-

3

L2L3

SHUNT

L1

CT-

2C

T-1

BR

EA

KE

R

GR

N/Y

EL

14G

A

GR

N/Y

EL

10G

AG

RN

/YE

L 10

GA

GR

OU

ND

TO G

EN

FR

AM

E

L0

ME

CH

AN

ICA

L LU

GS

12VDC(T

9)

GR

N/Y

EL

14G

A

GN

D

(L0)

BLKRE

D

CIR

CU

IT

2 3

BR

N

DE

UTS

CH

PLU

G31

PO

S C

ON

N2

XG

WY

XG

WY

XG

WY

50A

CIR

CU

IT

BLK

BLK

BLK

BLK

BLK

BLK

BLU

BR

EA

KE

R

50A

CIR

CU

ITB

RE

AK

ER

50A

CIR

CU

ITB

RE

AK

ER

BLK

BLK

BLK

BLK

BLK

BLK

BLU

BLU

BLU

BLU

20 A

MP

G.F

.I.O

UTL

ET

20 A

MP

G.F

.I.O

UTL

ET

20 A

MP

20 A

MP

BLK

BLK

BLK

BLK

BLK

BLK

BLK

RE

DB

LK

T4

GR

OU

ND

TOFR

AM

ET9T6 T8 T1

0

T11

T7 T1T2 T3

GE

NE

RAT

OR F+

F-

343329 30

3635

3231

37 38 39 40

T5T12

59

13

610

14

7 8

11 12

15 16

1 2 3 4

2 78

1

46

53

BR

N/W

HT

BR

N

RE

D

GN

/YL

BN

/WT

OR

G

YE

LV

OLT

RE

GU

LATI

ON

RE

LAY

1721

25

1822

26

19 20

23 24

27 28

RD

/BK

BLK

TO P

OW

ER

ZO

NE

PIN

40

BLK

TP2

TP3A

TP3

TP0

TP1

29

DE

UTS

CH

PLU

G31

PO

S C

ON

N2

28

DE

UTS

CH

PLU

G31

PO

S C

ON

N2

SE

E D

C P

RIN

TTO

TB

1 FU

SE

D &

SW

ITC

HE

D

RE

D

VO

LTA

GE

PM

500

A2

VR

1V

R2E3

F+ F-

5 A

MP

FUS

EO

N R

EG

ULA

TOR

50H

Z60

HZE2

E1 A1

RD

BK

WT

BK

AVR

PIN

STO

PO

WE

R Z

ON

E

RE

GU

LATO

R

P2

P1

BN

BN

/WT

BN

/WT

BN

TO P

OW

ER

ZO

NE

PIN

39

9047

2_O

RG

_08.

29.1

3

50

AC WIRING DIAGRAM - 4-POS. VOLT. SELECTOR SWITCH OPTION - MMG205

BR

N

GR

N/Y

EL

10G

A

(T7)

CT-

3

L2L3

SHUNT

L1

CT-

2C

T-1

BR

EA

KE

R

GR

N/Y

EL

14G

A

GR

N/Y

EL

10G

AG

RN

/YE

L 10

GA

GR

OU

ND

TO G

EN

FR

AM

E

L0

ME

CH

AN

ICA

L LU

GS

12VDC

(T9)

GR

N/Y

EL

14G

A

GN

D

(L0)

BKRD

3/0

CIR

CU

IT

P N

BR

N

DE

UTS

CH

PLU

G21

PIN

XG

WY

XG

WY

XG

WY

50A

CIR

CU

IT

BLK

BLK

BLK

BLK

BLK

BLK

BLU

BR

EA

KE

R

50A

CIR

CU

ITB

RE

AK

ER

50A

CIR

CU

ITB

RE

AK

ER

BLK

BLK

BLK

BLK

BLK

BLK

BLU

BLU

BLU

BLU

20 A

MP

G.F

.I.O

UTL

ET

20 A

MP

G.F

.I.O

UTL

ET

20 A

MP

20 A

MP

BKRD

3/0

3/0

3/0TO

PO

WE

R Z

ON

E P

IN 4

0

BLK

BLK

BLK

BLK

BLK

BLKORN

YEL

VO

LTA

GE

PM

500

A2

VR

1V

R2E3

F+ F-

5 A

MP

FUS

EO

N R

EG

ULA

TOR

50H

Z60

HZE2

E1 A1

RD

BK

WT

BK

RE

GU

LATO

R

AVR

PIN

STO

PO

WE

R Z

ON

E

P2

P1

BN

BN

/WT

BN

/WT

BN

TO P

OW

ER

ZO

NE

PIN

39

9047

0_O

RG

_08.

29.1

3

GR

OU

ND

TOFR

AM

E

GE

NE

RAT

OR

F+F-

T7

T10T11T12

T3 T2 T1 T4 T5 T6 T8 T9

1

57

162336

447

6556

61

52

6033

48

214

404

412668

7011

1932

8

VO

LT R

EG

ULA

TIO

NR

ELA

Y

YL

OR

BK WT/

BN

GN

RDBN

35

64

18

72

PO

WE

R S

WTO

CO

NTR

OL

SE

E D

C P

RIN

T

6

BN

/WT

TP1

51

AC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT

CIR

CU

ITB

RE

AK

ER

CA

MLO

CK

PA

NE

L

GN

DL0

L1L3

L2

65

8

7 2

VO

LTA

GE

RE

LAY

H1

H3

X2

X4

X1

X3

H2

H4

BK

RD

PO

WE

RR

ELA

Y

BK

BK

WH

T

BK

BU

CK

XF

OR

ME

R

BK

786

512

34

CO

M

NC

NO

E1

3F

+F

-7

6E

3/4

T9 T7G

EN

F+

F-

BN

BN

/WT

BK/WT

BN/WT

RD

BK

WT

BK

BN

(2.5

K, 2

WA

TT

)V

OLT

AG

EA

DJU

ST

ME

NT

T7

T9

PM

300

VO

LTA

GE

R

EG

ULA

TO

R

L1L3

L2

BN BN

BN

/WT

RE

CO

NN

EC

T

DO

OR

PM

G

B V

BN

BN/WT

DE

UT

SC

H21

PIN

CO

NN

-1

BN

/WT

CO

NN

-2

31 P

IN

DE

UT

SC

H

67

OR

T7

T9

L1L3

L2

BR

EA

KE

RC

IRC

UIT

GE

N

T1

T2

T3

T4 NE

UT

RA

LB

AR

L1 L2L0T7

T9

BR

OR

3334

CA

MLO

CK

PA

NE

L

GN

DL0

L1L3

L2A

LT

LUG

D

OO

RN

ON

-PO

WE

R

ZO

NE P

OW

ER

ZO

NE

CO

NT

RO

LO

NLY

3940

US

ED

ON

SO

ME

MO

DE

LS

NO

N-P

OW

ER

ZO

NE

WT

WT

NO

TE

: RE

PE

AT

ALT

CA

M L

OC

K F

OR

AD

DIT

ION

AL

SE

TS

.

S R

DE

UT

SC

H21

PIN

CO

NN

-2

OR

US

ED

ON

MM

G18

5A

ND

LO

WE

R

US

ED

ON

MM

G23

5

HIG

HE

RA

ND

NO

T C

ON

NE

CT

ED

TO

T7

& T

9 F

OR

V-F

LEX

CO

NN

EC

T T

O C

ON

N2

PO

S K

OR

NO

T C

ON

NE

CT

ED

TO

T9

FO

R V

-FLE

X O

R P

M50

0

V-F

LEX

ON

LY

3837P

OW

ER

ZO

NE

CO

NT

RO

L

SE

E P

OW

ER

ZO

NE

OP

TIO

N

CO

NN

-2

31 P

IN

DE

UT

SC

H

2 3

DE

UT

SC

H21

PIN

NPC

ON

N-1

OR

E1

P1

F+

F-

VR

1V

R2

E2

PM

500

VO

LTA

GE

R

EG

ULA

TO

RE

3P

2BN

A1

A2

BK

WT

(ALT

ER

NA

TE

)

600V

RE

LAY

PIN

4 W

HE

N E

QU

IPP

ED

CO

NN

EC

T T

O C

ON

N2

PO

S K

OR

600V

RE

LAY

PIN

4 W

HE

N E

QU

IPP

ED

CO

NN

EC

T T

O C

ON

N2

PO

S L

OR

600V

RE

LAY

PIN

8 W

HE

N E

QU

IPP

ED

TO

T7

TO

120

V B

RE

AK

ER

S

PM

G

BU

CK

TR

AN

SF

OR

ME

R

CA

M L

OC

KS

DE

DIC

AT

ED

240V

GE

N

TO

GE

N V

OLT

L3

TO

GE

N V

OLT

L1

TO

LU

GB

LOC

K

GR

OU

ND

TO

LU

GB

LOC

K

GR

OU

ND

TO

L0

TO

L0

GE

NE

RA

TO

RH

EA

TE

R

(ALT

ER

NA

TE

)

WT

BK

A2

A1

BN P2

E3

RE

GU

LAT

OR

PM

500

VO

LTA

GE

E

2V

R2

VR

1F

-F

+P

1E

1

ZO

NE

OP

TIO

NS

EE

PO

WE

R

PO

WE

R Z

ON

EC

ON

TR

OL

37 38

V-F

LEX

ON

LY

40 39

PO

WE

R Z

ON

EC

ON

TR

OL

ON

LY

RE

GU

LAT

OR

PM

300

VO

LTA

GE

AD

JUS

TM

EN

TV

OLT

AG

E(2

.5K

, 2 W

AT

T)

BN

BK

WT

BK

RD

BR/WT

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CO

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OM

NO

NO

NO

NO

++

++

--

--

RE

MO

TE C

OM

MU

NIC

ATIO

NR

ELA

Y B

OA

RD

12

34

56

1211

109

87

12

9041

6_L_

02.0

4.14

54

WIRING BLOCK DIAGRAM - DEDICATED 12 LEAD GENERATORS OPTION

LOL3

L2L1

TO C

ON

TRO

L B

OX

LOL3

L2L1

TO C

ON

TRO

L B

OX

LOL3

L2L1

TO C

ON

TRO

L B

OX

LOL3

L1TO

CO

NTR

OL

BO

X

LOL3

L1TO

CO

NTR

OL

BO

XLO

L3L2

L1TO

CO

NTR

OL

BO

X

TO G

EN

ER

ATO

R

480/

277V

3P

HH

IGH

WY

E

208/

120V

3P

H L

OW

WY

E

240/

120V

3P

HH

IGH

DE

LTA

120V

3P

HLO

W D

ELT

A24

0/12

0V 1

PH

LOW

ZIG

ZA

G

480/

240V

1 P

HH

IGH

ZIG

ZA

G

TO G

EN

ER

ATO

R

TO G

EN

ER

ATO

R

TO G

EN

ER

ATO

RTO

GE

NE

RAT

OR

L9

L7

T10T11T12T3T9T6T8T5T2T1T7T4

T1T7

T8T12

T3T9

T11T10T5T4

T9T6

T5T8

T11T2

T10T12T7T4T1

T3

T10

T3T9T6T1T4T7

T12T5T8T2

T6T2

T11T9T5T3

T8T4T2

T10

T6T7

T1

T12

T2T8

T11T12

T10T6T5T4

T3T9

T1T7

L9

L7

L9

L7

L9

L7

L9

L7

T11

TO G

EN

ER

ATO

R

NO

TE:

1. C

AB

LES

TO

CO

NTR

OL

BO

X M

AY C

ON

TAIN

1, 2

OR

3 W

IRE

S D

EP

EN

DIN

G O

N T

HE

MO

DE

L A

ND

VO

LTA

GE

.2.

AP

PLI

ES

TO

ALL

12

LEA

D G

EN

ER

ATO

RS

TO

BE

HA

RD

WIR

ED

IN G

EN

BO

X.

9030

2_A

_11.

06.1

2

55

TRAILER LIGHTS WIRING DIAGRAM

LAM

PLA

MP

LAM

P

FEN

DE

R

RE

D

LAM

PS

TOP

-TU

RN

SIG

NA

L LA

MP

RIG

HT

IDE

NTI

FIC

ATIO

NLI

GH

T B

AR PLA

TELA

MP

STO

P-T

UR

NS

IGN

AL

LAM

PR

IGH

T

MA

RK

ER

RE

DM

AR

KE

RA

MB

ER

MA

RK

ER

AM

BE

RM

AR

KE

R

RE

D

LAM

PM

AR

KE

RLA

MP

LAM

P

RE

DM

AR

KE

RA

MB

ER

MA

RK

ER

FEN

DE

RLA

MP

AM

BE

RM

AR

KE

R

TRA

ILE

RP

LUG

WT

BN YL

GN

BK

BK

BK

BK

BK

BK

BK

BK

BK

WT

BN

WT

BN

WT

BN

BN

WT

BN

GN

WT

BK

WT

WT

YL

BN

BN

WT

WT

BN

BK

BK

BK

BK

BK

BK

BK

BK

WT

BN

WT

BN

BKRD

WT

WT

RD

BK

6038

6_A

_02.

14.1

4

56

WIRING HARNESS - ELECTRIC BRAKE OPTION

BAT

TER

Y

BR

EA

KAW

AYS

WIT

CH

BL

WT

BK

BR

AK

EB

RA

KE

BL

BR

AK

EB

RA

KE

WT

TAN

DE

M A

XLE

BR

AK

E

BR

AK

E

TRI-A

XLE

SIN

GLE

AX

LE

SPLICE

SPLICE

SPLICE

SPLICE

SPLICE

SPLICE

SPLICE

SPLICE

SPLICE

SPLICE

SPLICE

SPLICE

BL

WT

BL

WT

SPLICE BK

BL

WT

SPLICE

BL

FRA

ME

GN

D

9028

6_E

_03.

18.1

4

57

SERVICE LOG

OIL GRADE AND TYPE: ____________________________ BRAND:___________________________________

COOLANT MIXTURE: ______________________________ BRAND:___________________________________

__________________________________________________________________________________________

__________________________________________________________________________________________

__________________________________________________________________________________________

__________________________________________________________________________________________

__________________________________________________________________________________________

__________________________________________________________________________________________

__________________________________________________________________________________________

__________________________________________________________________________________________

__________________________________________________________________________________________

__________________________________________________________________________________________

58

REV: BPART NO: 3372205.01.14

Documents

DIESEL GENERATOR MMG130D • MMG175 • MMG205 · Parts manuals available online! POWER PRODUCTS LLC DIESEL GENERATOR 175 With ControllerTM 00382 MMG130D • MMG175 • MMG205