POWER PRODUCTS LLC
DIESEL GENERATOR
MMG130D • MMG175 • MMG205
With
TM
Controller
175
00382
OPERATING MANUAL
Parts manuals available online! www.m-p-llc.com
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 LLC
215 Power Drive • Berlin, WI 54923
U.S.A.
Phone: 920-361-4442
FAX: 920-361-4416
Toll Free: 1-800-926-9768
www.m-p-llc.com
For technical or parts QUESTIONS, please contact the Magnum Power Products LLC Customer
Support or Technical Support team at 1-800-926-9768. Please have your serial number available.
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: _____________________________________
WARNING
CALIFORNIA 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 CONTENTS
Page
INTRODUCTION ................................................................................................................................ 2
SAFETY NOTES ................................................................................................................................ 6
OPERATING SAFETY ....................................................................................................................... 6
ENGINE SAFETY............................................................................................................................... 7
ELECTRICAL SAFETY ...................................................................................................................... 7
TOWING SAFETY.............................................................................................................................. 8
REPORTING TRAILER SAFETY DEFECTS ..................................................................................... 8
SAFETY SYMBOL SUMMARY .......................................................................................................... 9
SPECIFICATIONS - MMG130D ....................................................................................................... 10
SPECIFICATIONS - MMG175.......................................................................................................... 11
SPECIFICATIONS - MMG205.......................................................................................................... 12
UNIT DIMENSIONS ......................................................................................................................... 13
UNIT SERIAL NUMBER LOCATIONS ............................................................................................ 14
COMPONENT LOCATIONS ............................................................................................................ 15
MAIN CONTROL PANEL FEATURES ............................................................................................. 16
MAIN CONTROL PANEL FEATURES - WITH CAM LOCK OPTION .............................................. 18
POWER ZONE™ CONTROLLER.................................................................................................... 20
CONTROLLER FEATURES AND FUNCTIONS .............................................................................. 20
OPERATOR SCREENS ................................................................................................................... 21
MAINTENANCE SCREENS ............................................................................................................. 23
GENERATOR MONITORING .......................................................................................................... 26
ENGINE MONITORING ................................................................................................................... 26
DIESEL EXHAUST FILTER MONITORING ..................................................................................... 26
POWER ZONE™ CONTROLLER INFORMATION DISPLAYS, FUNCTIONS, AND RESET ......... 27
GENERATOR OUTPUT CONNECTION LUGS ............................................................................... 28
GENERATOR CAM LOCK CONNECTION(S) OPTION .................................................................. 28
VOLTAGE SELECTOR SWITCH ..................................................................................................... 29
PRESTART CHECKLIST ................................................................................................................. 31
ENGINE BREAK-IN REQUIREMENTS............................................................................................ 31
EMERGENCY STOP SWITCH ........................................................................................................ 31
MANUAL STARTING OF THE UNIT................................................................................................ 32
AUTO (REMOTE) STARTING OF THE UNIT .................................................................................. 33
VOLTAGE REGULATION ................................................................................................................ 33
DERATING FOR ALTITUDE ............................................................................................................ 34
WET STACKING .............................................................................................................................. 34
CONTROL PANEL RECEPTACLES................................................................................................ 34
MAIN CIRCUIT BREAKER............................................................................................................... 35
REMOTE START TERMINAL BLOCK ............................................................................................. 35
TRANSFER SWITCH ....................................................................................................................... 35
AUTO EXERCISE TIMER ................................................................................................................ 36
FINE VOLTAGE ADJUSTMENT ...................................................................................................... 38
SHUTTING DOWN THE UNIT ......................................................................................................... 38
EXHAUST FILTER CLEANING OPERATIONS ............................................................................... 38
TOWING THE UNIT ......................................................................................................................... 39
LIFTING THE UNIT .......................................................................................................................... 40
DAILY WALK AROUND INSPECTION ............................................................................................ 40
GENERAL MAINTENANCE ............................................................................................................. 40
BASIC MAINTENANCE SCHEDULE - JOHN DEERE ENGINE ...................................................... 41
RESETTING THE MAINTENANCE ALARMS.................................................................................. 42
BELT TENSIONERS ........................................................................................................................ 43
EXHAUST FILTER SERVICE REQUIREMENTS ............................................................................ 43
ECU OVERRIDE SWITCH ............................................................................................................... 43
CHECKING GENERATOR DRIVE PLATE TORQUE ...................................................................... 43
JACK MAINTENANCE ..................................................................................................................... 44
TRAILER WHEEL BEARINGS ......................................................................................................... 44
TROUBLESHOOTING AUTOMATIC SHUTDOWN CONDITIONS ................................................. 44
VISCOUS FAN CLUTCH OPTION................................................................................................... 46
AC WIRING DIAGRAM - 3 POSITION VOLTAGE SELECTOR SWITCH - MMG130D ................... 47
3
AC WIRING DIAGRAM - 3 POSITION VOLTAGE SELECTOR SWITCH - MMG175 ..................... 48
AC WIRING DIAGRAM - 3 POSITION VOLTAGE SELECTOR SWITCH - MMG205 ..................... 49
AC WIRING DIAGRAM - 4-POS. VOLT. SELECTOR SWITCH OPTION - MMG130D, MMG175 .. 50
AC WIRING DIAGRAM - 4-POS. VOLT. SELECTOR SWITCH OPTION - MMG205...................... 51
AC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT ................................................................ 52
DC WIRING DIAGRAM .................................................................................................................... 53
DC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT................................................................ 54
WIRING BLOCK DIAGRAM - DEDICATED 12 LEAD GENERATORS OPTION ............................. 55
TRAILER LIGHTS WIRING DIAGRAM ............................................................................................ 56
WIRING HARNESS - ELECTRIC BRAKE OPTION......................................................................... 57
SERVICE LOG ................................................................................................................................. 58
4
This Page Intentionally Left Blank
5
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.
DANGER
INDICATES A HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN
DEATH OR SERIOUS INJURY.
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION
Indicates 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:
6
•
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).
•
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:
Administrator
NHTSA
1200 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.
Safety alert symbol; used to
alert you to potential personal
injury hazards.
Asphyxiation hazard; operate
in well ventilated area.
Hot surface(s) nearby.
Dangerous voltage may be
present.
Belt/entanglement hazard; keep
body parts clear of this area.
Anchor/tie down point.
Fan hazard; keep body parts
clear of this area.
Isolate generator to prevent
electrocution hazard.
Never change switch position
while engine is running.
Use clean diesel fuel only.
Stop engine before making
connections.
Remove negative battery
cable before performing
any service on unit.
Stop engine before fueling.
Read and understand the
supplied operator’s manual
before operating unit.
Hearing protection required
while operating unit with doors
open.
Unit electrical ground.
Lift here only.
Fire/explosion hazard; keep
open flames away from unit.
Engine running.
Burn/scald hazard;
pressurized steam.
Exhaust Filter Cleaning enabled.
Exhaust Filter Cleaning disabled.
00383
9
SPECIFICATIONS - MMG130D
MAGNUM MODEL
MMG130D
MMG130D Super Start
Engine
Make/Brand...................................................................... John Deere ...................................John Deere
Model ............................................................................... PE4045HFG93..............................PE4045HFG93
EPA Tier ........................................................................... 4i ...................................................4i
Horsepower - prime hp (kW) .......................................... 152 (113).......................................152 (113)
Horsepower - standby hp (kW) ....................................... 166 (124).......................................166 (124)
Operating Speed rpm ..................................................... 1800 ..............................................1800
Displacement in3 (L) ........................................................ 275 (4.5)........................................275 (4.5)
Cylinders - qty .................................................................. 4 ....................................................4
Fuel Consumption - 100% prime gph (Lph) ................... 7.4 (28.0).......................................7.4 (28.0)
Battery Type..................................................................... Group 24 .......................................Group 24
Battery Voltage (Quantity per Unit) .................................. 12V (1) ..........................................12V (1)
Battery Rating .................................................................. 1000 CCA .....................................1000 CCA
Generator
Make/Brand...................................................................... Marathon Electric ..........................Marathon Electric
Model ............................................................................... 363PSL1607 .................................431CSL6206
Type, 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 ................................................450
1Ø - Prime kW (kVA) ...................................................... 90 (90)...........................................98 (98)
Amps - 1Ø Prime - 240V A ............................................. 375 ................................................408
Frequency Hz .................................................................. 60 ..................................................60
Power Factor.................................................................... 1 (1Ø), 0.8 (3Ø).............................1 (1Ø), 0.8 (3Ø)
Sound dB(A) 23 ft @ prime ............................................ 68 ..................................................68
Weights
Dry 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.
Capacities
Fuel 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 Distribution
Circuit Breaker Size ......................................................... 450 ................................................450
Voltage 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, 277
Voltages Available 3Ø ...................................................... 208, 220, 440, 480 ........................208, 220, 440, 480
Trailer
Number of Axles .............................................................. 2 ....................................................2
Capacity - Axle Rating lbs (kg) ....................................... 6000 (2722)...................................6000 (2722)
Tire Size in ...................................................................... 16 ..................................................16
Brakes.............................................................................. Surge ............................................Surge
Hitch - Standard ............................................................... 3" Ring ..........................................3" Ring
Maximum Tire Pressure psi ............................................ 75 ..................................................75
Specifications are subject to change without notice.
10
SPECIFICATIONS - MMG175
MAGNUM MODEL
MMG175
MMG175 Super Start
Engine
Make/Brand...................................................................... John Deere ...................................John Deere
Model ............................................................................... PE6068HFG94..............................PE6068HFG94
EPA Tier ........................................................................... 4i ...................................................4i
Horsepower - prime hp (kW) .......................................... 217 (162).......................................217 (162)
Horsepower - standby hp (kW) ....................................... 241 (180).......................................241 (180)
Operating Speed rpm ..................................................... 1800 ..............................................1800
Displacement in3 (L) ....................................................... 415 (6.8)........................................415 (6.8)
Cylinders - qty .................................................................. 6 ....................................................6
Fuel Consumption - 100% prime gph (Lph) ................... 10.9 (41.3).....................................10.9 (41.3)
Battery Type..................................................................... Group 31 .......................................Group 31
Battery Voltage (Quantity per Unit) .................................. 12V (1) ..........................................12V (1)
Battery Rating .................................................................. 1000 CCA .....................................1000 CCA
Generator
Make/Brand...................................................................... Marathon Electric ..........................Marathon Electric
Model ............................................................................... 431PSL6306 .................................432PSL6210
Type, 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 ................................................654
1Ø - Prime kW (kVA) ...................................................... 120 (120).......................................143 (143)
Amps - 1Ø Prime - 240V A ............................................. 500 ................................................596
Frequency Hz .................................................................. 60 ..................................................60
Power Factor.................................................................... 1 (1Ø), 0.8 (3Ø).............................1 (1Ø), 0.8 (3Ø)
Sound dB(A) 23 ft @ prime ............................................ 68 ..................................................68
Weights
Dry 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.
Capacities
Fuel 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 ................................................. 29 ..................................................29
AC Distribution
Circuit Breaker Size ......................................................... 700 ................................................700
Voltage 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, 277
Voltages Available 3Ø ...................................................... 208, 220, 440, 480 ........................208, 220, 440, 480
Trailer
Number of Axles .............................................................. 2 ....................................................2
Capacity - Axle Rating lbs (kg) ....................................... 6000 (2722)...................................6000 (2722)
Tire Size in ...................................................................... 16 ..................................................16
Brakes.............................................................................. Surge ............................................Surge
Hitch - Standard ............................................................... 3" Ring ..........................................3" Ring
Maximum Tire Pressure psi ............................................ 75 ..................................................75
Specifications are subject to change without notice.
11
SPECIFICATIONS - MMG205
MAGNUM MODEL
MMG205
MMG205 Super Start
Engine
Make/Brand...................................................................... John Deere ...................................John Deere
Model ............................................................................... PE6068HFG95..............................PE6068HFG95
EPA Tier ........................................................................... 4i ...................................................4i
Horsepower - prime hp (kW) .......................................... 252 (188).......................................252 (188)
Horsepower - standby hp (kW) ....................................... 268 (200).......................................268 (200)
Operating Speed rpm ..................................................... 1800 ..............................................1800
Displacement in3 (L) ....................................................... 415 (6.8)........................................415 (6.8)
Cylinders - qty .................................................................. 6 ....................................................6
Fuel Consumption - 100% prime gph (Lph) ................... 12.8 (48.5).....................................12.8 (48.5)
Battery Type..................................................................... Group 31 .......................................Group 31
Battery Voltage (Quantity per Unit) .................................. 12V (1) ..........................................12V (1)
Battery Rating .................................................................. 1000 CCA .....................................1000 CCA
Generator
Make/Brand...................................................................... Marathon Electric ..........................Marathon Electric
Model ............................................................................... 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 ................................................176
Amps - 1Ø Standby - 240V A .......................................... 646 ................................................733
1Ø - Prime kW (kVA) ...................................................... 142 ................................................167
Amps - 1Ø Prime - 240V A ............................................. 592 ................................................696
Frequency Hz .................................................................. 60 ..................................................60
Power Factor.................................................................... 1 (1Ø), 0.8 (3Ø).............................1 (1Ø), 0.8 (3Ø)
Sound dB(A) 23 ft @ prime ............................................ 68 ..................................................68
Weights
Dry 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.
Capacities
Fuel 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 ................................................. 24 ..................................................24
AC Distribution
Circuit Breaker Size ......................................................... 800 ................................................800
Voltage 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, 277
Voltages Available 3Ø ...................................................... 208, 220, 440, 480 ........................208, 220, 440, 480
Trailer
Number of Axles .............................................................. 2 ....................................................2
Capacity - Axle Rating lbs (kg) ....................................... 6000 (2722)...................................6000 (2722)
Tire Size in ...................................................................... 16 ..................................................16
Brakes.............................................................................. Surge ............................................Surge
Hitch - Standard ............................................................... 3" Ring ..........................................3" Ring
Maximum Tire Pressure psi ............................................ 75 ..................................................75
Specifications are subject to change without notice.
12
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)
H
W
L
H
W
L
00384
Specifications are subject to change without notice.
13
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
UNIT ID Tag
GAWR / PNBE
Manufactured by Magnum Power Products, LLC.,
a subsidiary of Generac Power Systems, Inc.
(920) 361-4442
(800) 926-9768
Model
Serial Number
Weight (lbs/kg)
RPM/Frequency
Rating
1 ph. 1.0PF
3 ph. .8PF
A
RIM / JANTE
DATE:
00/0000
COLD INF. PRESS./
PRESS. DE
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.
3 ph. 1.0PF
Ins. Class
TIRE AND LOADING INFORMATION
RENSEIGNEMENTS SUR LES
PNEUS ET LE CHARGEMENT
GONF A FROID - KPA(PSI/LPC) SGL / DUAL
The weight of cargo should never exceed 0000KG (0000LBS)
Le poids du chargement ne doit jamais depasser 0000KG (0000LBS)
KW
V
TIRE / PNEU
EACH
AXLE
Country of Origin
Manufacturing Code
KVA
(located on opposite side of trailer)
MANUFACTURED BY/FABRIQUE PAR: Magnum Power Products LLC
GVWR/PNBV: 000KG (0000LBS)
V.I.N./N.I.V.:
00000000000000000
XXX000
TRAILER
MODEL:
TYPE:
SEE OWNER’S
MANUAL FOR
ADDITIONAL
INFORMATION
VOIR LE
MANUEL DE
L’USAGER
POUR
PLUS DE
RENSEIGNEMENTS
FOR ELECTRICAL EQUIPMENT
ONLY. POUR MATERIAL
ELECTRIQUE SEULEMENT.
209649
Form: SFC626B
00385
14
COMPONENT LOCATIONS
Central
Lift Point
Engine
Access
Voltage Selector
Access
Fuel Fill
Engine Battery
Access
Ladder
Radiator
Access Panel
Engine
Exhaust
Ladder
Engine
Access
Control
Panel
Access
Emergency
Stop
Oil Drain
Port
Radiator
Drain Port
00386
15
MAIN CONTROL PANEL FEATURES
1
2
3
4
15
5
14
6
7
13
12
10
11
16
9
8
00387
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
2
1
16
15
3
4
14
5
6
13
7
12
11
10
18
9
8
00388
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.
Operator
Screens
Power Zone™ Controller
STARTING THE GENERATOR
DAS STARTEN DES GENERATORS
COMIENZO DEL GENERADOR
COMMENCEMENT DU GÉNÉRATEUR
Home
CONTROL
ON
I
1. PRESS CONTROL POWER
SWITCH “ON”
O
CONTROL
OFF
2. PUSH ENGINE START “I”
Engine
Navigation
Buttons
CONTROL ON
Generator
I
Voltage
O
Control
Power
Switch
CONTROL OFF
Alarm
Mute
STOPPING THE GENERATOR
DAS AUFHÖREN DES GENERATORS
PARADA DEL GENERADOR
ARRÊT DU GÉNÉRATEUR
1. PUSH ENGINE STOP “O”
CONTROL
ON
Auto /
Manual
Mode
2. PRESS CONTROL POWER
SWITCH “OFF”
I
O
CONTROL
OFF
LCD Window
Engine Stop / Reset
Engine Start
(Manual Mode)
00389
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 ( GEN ), and Voltage Adjust ( + V - ). For information about the
screens, refer to “Operator Screens” on page 21.
ALARM MUTE
The Alarm Mute (
alarm.
) button silences the audible alarm. Additional action will be required to fully disable the active
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.
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.
CAUTION
In 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.
Manual Mode
Time to Empty
15 hr
106.9 kW
80
110
90 100
70
60
GEN
50
40
+V -
30
20
10
0
%
Full
3 PHASE
Volts
3/4
480
1/2
1/4
Amps
128
Empty
74
%
00393
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.
Manual Mode
40
190
60
20
80
100
0
GEN
20
230
150
250
50.9 PSI
Oil press.
+V -
210
170
40
0
50
214 °F
13.8 V
Coolant Temp.
Battery
0 0 3 2 5
Maintenance
Alarm
Hours
1 174 To Service
2 174 To Service
3 174 To Service
30
10
1 5
Hrs
Description
Oil Maintenance
Fuel Maintenance
Air Maintenance
Action
Warning
Shutdown
Electrical Trip
00394
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 lineto-line voltage, and individual line-to-neutral voltage, amperage and power (kW). This screen also displays the
generator winding configuration set by the voltage selector switch in the lower right corner.
Manual Mode
30
GEN
175
40
20
50
10
25
88
263
13
38
60
Freq
0
70
0
Volt
350
0
Amp
50
+V Volt
L1-L2
L2-L3
L3-L1
Volt
0
0
0
L1
L2
L3
IE
Amp
0
0
0
0
25
50
0
Parallel Low Zig-Zag
kW
0.0
0.0
0.0
L1 (U)
N
L2 (W)
00395
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.
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 electronically 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.
Manual Mode
Voltage Adjust
- Press , voltage will begin flashing
- Use
and
arrows to adjust voltage
- Press
to confirm new voltage. Numbers will stop flashing
GEN
+V -
480
277
V L-N Average
V L-L Average
00396
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.
SITE
GENSET
7741 \ 7740
480V/277V 3-Phase
Return Delay
10:00:00
Total
0.0 Hz
kW
kVAr
0.0 %
0.0 %
0.0 kW
0.0 kVA
0.0 kVAr
0.00 pf
07:10
Generator
0.0 kWh+
0.0 kVAh
0.0 kVArh
00397
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.
23
Note: The content may change depending upon the selected engine and the features supported by the engine.
SITE
GENSET
7741 \ 7740
07:10
480V/277V 3-Phase
Return Delay
10:00:00
Total
0.0 kW
0.0 kVA
0.0 kVAr
0.00 pf
0.0 Hz
0.0 %
0.0 %
kW
kVAr
12
9
15
CAN
21
+ -
4
0
36
50
7
8
9
0
10
70
20
80
10
-50
250
90
0
100
0 °F
Oil press.
0%
Coolant Temp.
100
50
60
30
200
0.00 PSI
33
50
40
150
0
1
30
0 0 0 0 0 0 0 Hrs
Engine Starts
100
6
2
27
0 RPM
5
3
24
3
V
0.0 kVAh
0.0 kVArh
18
6
GEN
Generator
0.0 kWh+
20
150
10
0
200
-50
250
Fuel Level
30
20
40
30
10
40
Fuel Used
US Gal
Engine
1/9
Generator
50
0
50
0 °F
0.0 V
0.0 V
Oil Temp
Battery
Charge Alt
Fuel Remaining
Litre
0
Alarms
Schedule
I/O
Status
00396
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.
SITE
GENSET
7741 \ 7740
07:10
480V/277V 3-Phase
Return Delay
10:00:00
Total
0.0 kW
0.0 kVA
0.0 kVAr
0.00 pf
0.0 Hz
0.0 %
0.0 %
kW
kVAr
300
300
400
200
GEN
300
400
200
Generator
0.0 kWh+
0.0 kVAh
0.0 kVArh
30
40
400
200
20
500
100
500
100
50
500
100
10
Volt
+V -
Volt
L1-L2
L2-L3
L3-L1
600
Volt
0
0
0
L1
L2
L3
Engine
kW
0
0
0
0
IE
1/9
600
Generator
0
70
L3-L1
Amp
0
0
0
Freq
0
L2-L3
Volt
L1-L2
60
Volt
0
600
0
Hz
kVA
0.0
0.0
0.0
Alarms
I/O
kVAr
0.0
0.0
0.0
pf
0.0
0.0
0.0
Schedule
0.0
0.0
0.0
Status
00399
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.
SITE
GENSET
7741 \ 7740
07:10
480V/277V 3-Phase
Return Delay
10:00:00
Total
0.0 Hz
0.0 %
0.0 %
kW
kVAr
Warning
Shutdown
0.0 kW
0.0 kVA
0.0 kVAr
0.00 pf
Generator
0.0 kWh+
0.0 kVAh
0.0 kVArh
Electrical Trip
GEN
+V -
Engine
1/2
Engine
Generator
Alarms
I/O
Schedule
Status
00400
24
Alarm Type
Color Background/Text
Graphic
Warning
Yellow/Black
Warning
Electrical Trip
Purple/Black
Electrical Trip
Shutdown
Red/Black
Shutdown
ECU Code
Blue/White
Engine
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.
SITE
GENSET
7741 \ 7740
07:10
480V/277V 3-Phase
Return Delay
10:00:00
Total
0.0 Hz
0.0 %
0.0 %
kW
kVAr
GEN
+V -
Index
1
2
3
4
5
6
7
8
9
10
11
12
13
Date
01/01/1970
02/06/1970
01/01/1970
01/01/1970
01/01/1970
01/01/1970
01/01/1970
01/01/1970
01/01/1970
01/01/1970
01/01/1970
01/01/1970
01/01/1970
2/2
Engine
Time
00:00:01
11:45:55
00:00:00
00:00:00
00:00:00
00:00:00
00:00:00
00:00:00
00:00:00
00:00:00
00:00:00
00:00:00
00:00:00
Hrs
0:00
0:00
0:00
0:00
0:00
0:00
0:00
0:00
0:00
0:00
0:00
0:00
0:00
Event
Shutdown
Shutdown
Warning
Shutdown
Shutdown
Shutdown
Shutdown
Shutdown
Shutdown
Shutdown
Shutdown
Shutdown
Shutdown
Generator
Alarms
Generator
0.0 kWh+
0.0 kW
0.0 kVA
0.0 kVAr
0.00 pf
0.0 kVAh
0.0 kVArh
Details
This is an event index 1
This is an event index 2
This is an event index 3
This is an event index 4
This is an event index 5
This is an event index 6
This is an event index 7
This is an event index 8
This is an event index 9
This is an event index 10
This is an event index 11
This is an event index 12
This is an event index 13
Schedule
I/O
Status
00405
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.
SITE
GENSET
7741 \ 7740
07:10
480V/277V 3-Phase
Return Delay
10:00:00
Total
0.0 Hz
0.0 %
0.0 %
kW
kVAr
0.0 kW
0.0 kVA
0.0 kVAr
0.00 pf
Generator
0.0 kWh+
0.0 kVAh
0.0 kVArh
Digital Inputs
GEN
+V -
Ip Description
Active
State
Ip Description
A
G
B
H
C
I
D
J
E
K
Active
State
F
1/38
Engine
Generator
Alarms
I/O
Schedule
Status
00406
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
25
condition.
SITE
GENSET
7741 \ 7740
07:10
480V/277V 3-Phase
Return Delay
10:00:00
Total
0.0 Hz
0.0 %
0.0 %
kW
kVAr
GEN
+V -
Scheduler Enabled to run Reserved Reserved
Event Week
Day
Start
Stop Duration
All
Monday
00:00 00:00
0:00
1
2
All
Monday
00:00 00:00
0:00
All
Monday
00:00 00:00
0:00
3
4
All
Monday
00:00 00:00
0:00
All
Monday
00:00 00:00
0:00
5
All
Monday
00:00 00:00
0:00
6
All
Monday
00:00 00:00
0:00
7
All
Monday
00:00 00:00
0:00
8
Maintenance
Alarm
Hours
1
250:00
2
500:00
3 3000:00
1/1
Date
Event
9
10
11
12
13
14
15
16
Time
Week
All
All
All
All
All
All
All
All
Generator
0.0 kWh+
0.0 kW
0.0 kVA
0.0 kVAr
0.00 pf
Day
Monday
Monday
Monday
Monday
Monday
Monday
Monday
Monday
0.0 kVAh
0.0 kVArh
Start
00:00
00:00
00:00
00:00
00:00
00:00
00:00
00:00
Stop Duration
00:00
0:00
00:00
0:00
00:00
0:00
00:00
0:00
00:00
0:00
00:00
0:00
00:00
0:00
00:00
0:00
Description
Action
Warning
Warning
Warning
250 hr Maint. - Refer to Manual
500 hr Maint. - Refer to Manual
3000 hr Maint. - Refer to Manual
Engine
Generator
Alarms
Schedule
I/O
Status
00407
STATUS TAB
The Status tab contains the status and configuration of the controller, firmware and data connections.
SITE
GENSET
7741 \ 7740
07:10
480V/277V 3-Phase
Return Delay
10:00:00
Total
0.0 Hz
0.0 %
0.0 %
kW
kVAr
GEN
Model
Application
USB ID
Supervisor State:
Engine State:
Load State:
Model
Application
USB ID
Bootloader
Ethernet
+V -
Link Quality
- CTS
- RTS
- DTR
- DSR
- DCD
1/1
Engine
Generator
100%
Protections:
Logging
Log Dest:
Log Mode:
USB drive:
Host IP:
Host Port:
Alarms
I/O
Generator
0.0 kWh+
0.0 kW
0.0 kVA
0.0 kVAr
0.00 pf
0.0 kVAh
0.0 kVArh
Bootloader
Analogue
Engine:
Total mem
Log mem free
Log Time:
Slave IP:
Slave Port:
Schedule
Status
00408
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:
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 Status
HEST Lamp - Solid
DPF Lamp
DPF Inhib
6/6
Engine
Generator
Alarm
Alarms
Schedule
I/O
Status
00409
•
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 Status
DPF Status
HEST Lamp
DPF Lamp - Solid
DPF Inhib
6/6
Engine
Generator
HEST Lamp
Alarm
Alarms
I/O
DPF Lamp - Flashing
DPF Inhib
Schedule
Status
6/6
Engine
Generator
Alarm
Alarms
I/O
Schedule
Status
00410
•
DPF Inhib: This area will display the Disabled Regeneration indicator above the words “DPF Inhib - Solid”
when auto exhaust filter cleaning is disabled.
DPF Status
HEST Lamp
DPF Lamp
DPF Inhib - Solid
6/6
Engine
Generator
Alarms
Alarm
I/O
Schedule
Status
00411
•
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.
DPF Status
HEST Lamp
DPF Lamp
DPF Inhib
6/6
Engine
Generator
Alarm - Solid
Alarms
I/O
Schedule
Status
00412
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.
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.
WARNING
It 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, personal injury, or death.
WARNING
Before 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.
DANGER
IMPROPER 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.
RUN CABLES THROUGH
OPENING IN BOTTOM
OF LUG BOX
WARNING
Never 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.
00450
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.
WARNING
It 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, personal injury or death.
28
WARNING
Before 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.
DANGER
IMPROPER 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.
CAM LOCK PANEL
L1
L2
L3
N (Neutral)
G (Ground)
Black
Red
Blue
White
Green
00451
WARNING
NEVER 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.
WARNING
Some 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
29
setting is prevented.
277/480V 3-PHASE
L1-L2 = 480V
L2-L3 = 480V
L3-L1 = 480V
120/
208V
277/
480V
L1-N = 277V
L2-N = 277V
L3-N = 277V
N=
VOLTAGES AT RECEPTACLES
RECEPTACLE
L-L
L-N
GFCI
139V
GFCI w/Buck
120V
Twist-locks
240V
139V
Switch styles vary by model.
00083
120/208V 3-PHASE
L1-L2 = 208V
L2-L3 = 208V
L3-L1 = 208V
120/
208V
120/
240V
277/
480V
L1-N = 120V
L2-N = 120V
L3-N = 120V
N=
VOLTAGES AT RECEPTACLES
RECEPTACLE
L-L
L-N
GFCI
120V
GFCI w/Buck
120V
Twist-locks
208V
120V
Switch styles vary by model.
00085
120/240V 3-PHASE
120/
208V
L1-L2 = 240V
L2-L3 = 240V
L3-L1 = 240V
120/
240V 3PH
277/
480V
120/
240V
1PH
Switch styles vary by model.
L1-N = 120V
L2-N = 208V
L3-N = 120V
N=
VOLTAGES AT RECEPTACLES
RECEPTACLE
L-L
L-N
GFCI
120V
GFCI w/Buck
120V
Twist-locks
120V
0/120V
4 Position Voltage Selector Switch Option
00086
120/240V 1-PHASE
L1-L2 = L2-L3 = L3-L1 = 240V
120/
208V
120/
240V
Switch styles vary by model.
L1-N = 120V
L2-N = L3-N = 120V
N=
VOLTAGES AT RECEPTACLES
RECEPTACLE
L-L
L-N
GFCI
120V
GFCI w/Buck
120V
Twist-locks
240V
120V
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.
ER
GEN
Y
STOP
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.
M
C
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.
E
EMERGENCY STOP SWITCH
00230
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
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.
DANGER
CARBON 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.
TM
Image File Transer...
82%
00414
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.
Stop Mode
Time to Empty
15 hr
0.0 kW
80
110
90 100
70
60
GEN
50
40
+V -
30
20
10
0
%
Full
3 PHASE
Volts
3/4
0
1/2
1/4
Amps
0
Empty
74
%
00415
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.
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 receptacles rated at 50A each. The smaller duplex receptacles 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 receptacle.
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.
34
20A Circuit
Breakers
50A Circuit
Breakers
120V GFCI
Receptacles
120/240V
Twist-Lock
Receptacles
00453
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:
On/I
On/I
Off/O
Off/O
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.
00452
Make sure any problems that cause the main circuit breaker to trip are corrected before returning the switch to the
ON (I) position.
WARNING
The 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.
Remote Start
Switch Terminals
00231
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.
35
DANGER
FAILURE 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.
Incoming
Utility
Power
Utility
Meter
Emergency
Distribution Panel
(Generator Power)
Main
Distribution Panel
(Utility Power)
Transfer
Switch
WHITE = Incoming
Utility Power
GRAY = Normal Utility
Power Circuit
BLACK = Emergency
Generator Power Circuit
Power From
Generator
00206
WARNING
ONLY 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.
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.
Item
Values
Enable
Yes/No
Run Mode
Monthly/Weekly
Load
Idle, In Island, On Load, Off Load
3. Access the Scheduler Setup section. Within this section, each schedule entry can be modified by pressing the
 button to select the item and the ▲ and ▼ buttons to define them.
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
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
until Auto mode is displayed at the top of the screen.
button for five seconds, or
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.
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.
Manual Mode
Voltage Adjust
- Press , voltage will begin flashing
- Use
and
arrows to adjust voltage
- Press
to confirm new voltage. Numbers will stop flashing
GEN
+V -
480
277
V L-N Average
V L-L Average
00396
1. With the unit running, press + V - .
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 involvement. 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.
38
WARNING
The 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 components 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).
1
4
3
2
5
Note: After the first road use, re-torque the lug nuts in sequence.
00204
6. Maximum recommended speed for highway towing is 45 mph (72 km/h). Recommended off-road towing speed is not to exceed 10 mph (16 km/h) or less, depending on terrain.
LIFTING THE UNIT
Central Lift Point
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 equipment being used to raise the unit has sufficient capacity.
For approximate weights, refer to Specifications beginning on page 10. Always remain aware of others around
you when moving or lifting the unit. Keep the doors closed
and locked.
00419
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.
•
•
•
•
•
•
40
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.
•
•
•
•
•
•
•
•
•
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
Daily
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







*

250
Hrs.
500
Hrs./12
Months
3000
Hrs./ 36
Months
As
Required

**


41
Item
Daily
250
Hrs.
500
Hrs./12
Months
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
*
**
3000
Hrs./ 36
Months
As
Required














Replace primary air cleaner when dust valve restriction indicator gauge shows a vacuum of 25 in. H2O.
Change the oil and oil filter after the first 100 hours, then every 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.
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.
CAUTION
Do not remove ash by using water or other chemicals. Removing ash by these methods
may cause equipment damage and create unsafe operating conditions.
CAUTION
Only a qualified service provider should remove, handle and dispose of 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.
2.
3.
4.
Utilize the Automatic Exhaust Filter Cleaning mode.
Avoid unnecessary idling.
Use proper engine oil. Refer to the engine operator’s manual.
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.
00420
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
MMG130D
ft-lbs (Nm)
36 (49)
43
MMG175
46 (63)
MMG205
47 (64)
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
•
Oil
Apply a lightweight oil to the screw stem.
Grease
Grease
Grease
Oil
Oil
Oil
Oil
00243
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
WARNING
Allow 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
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.
2.
3.
4.
Check the fuel level in the tank.
Check for proper operation of the fuel pump.
Check the air filter for blockage.
If the engine will not start, refer to the engine operator’s manual for additional information on troubleshooting starting problems.
OVERSPEED OR UNDERSPEED SHUTDOWN
1. Disconnect all loads and restart the generator. Read the frequency (Hz) on the LCD 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
120V
GFCI
RECPT
MECHANICAL LUGS
L1
L2
L3
L0
GND
120V
GFCI
RECPT
120V
20A
BRKER
GROUND
TO GEN FRAME
GRN/YEL
GRN/YEL
GRN/YEL
GRN/YEL
GRN/YEL
12VDC
SHUNT
MAIN
CIRCUIT
BREAKER
120V
20A
BRKER
BRN
BRN
WIRES NOT USED IN
BUCK BOOST OPTION
BLK
BLK
240V 50A
BREAKER
BLK
240V 50A
BREAKER
BLK
240V 50A
BREAKER
BLK
240V
50A
RCPT.
BLK
TO POWER ZONE PIN 40
BLK
(T7)
PAIR BLK
BLK
PAIR BLK
(T9)
BLK
BLK
L0
BLK
CT-1
CT-2
240V
50A
RCPT.
BLK
LT BLU
LT BLU
LT BLU
LT BLU
LT BLU
PAIR BLK
(L0)
SEE DC WIRING DIAGRAM
FOR CT CONNECTIONS
240V
50A
RCPT.
BLK
CT-3
TP5
T5
BLK
BLK
BLK
T4
T9
13
1
5
9
2
6
10
17
14
18
21
22
25
26
T6
T8
T10
T11
T7
T1
T12
TP1
L1
3
4
7
8
11
15
12
16
19
20
23
27
24
28
GENERATOR
F+ F-
GROUND
TO
FRAME
JUMPER WIRE ON
PHASE SWITCH
12-17
T2
TP2
L2
TP4
P2
P1
E1
E2
E3
F+
FA2
5 AMP FUSE
A1
ON REGULATOR VR1
VR2
50HZ
60HZ
TP3
T3
L3
PM500
VOLTAGE
REGULATOR
BN
BN/WT
BN/WT
BN
RD
BK
WT
BK
AC PLUG
15-PIN
TO POWER ZONE PIN 39
RED
BLK
TO POWER ZONE
AVR PINS
90473_ORG_08.29.13
47
AC WIRING DIAGRAM - 3 POSITION VOLTAGE SELECTOR SWITCH - MMG175
L2
L3
L0
120V
GFCI
RECPT
120V
GFCI
RECPT
MECHANICAL LUGS
L1
GND
120V
20A
BRKER
120V
20A
BRKER
GROUND
TO GEN FRAME
GRN/YEL
GRN/YEL
GRN/YEL
12VDC
SHUNT
MAIN
CIRCUIT
BREAKER
GRN/YEL
GRN/YEL
BRN
BRN
WIRES NOT USED IN
BUCK BOOST OPTION
BLK
BLK
240V 50A
BREAKER
BLK
240V 50A
BREAKER
BLK
240V 50A
BREAKER
BLK
240V
50A
RCPT.
BLK
TO POWER ZONE PIN 40
BLK
(T7)
PAIR BLK
BLK
PAIR BLK
(T9)
BLK
BLK
CT-1
CT-2
CT-3
L0
BLK
T5
BLK
BLK
T4
BLK
240V
50A
RCPT.
BLK
LT BLU
LT BLU
LT BLU
LT BLU
LT BLU
PAIR BLK
(L0)
SEE DC WIRING DIAGRAM
FOR CT CONNECTIONS
240V
50A
RCPT.
BLK
T9
13
1
5
9
2
6
10
17
14
18
21
22
25
26
T6
T8
T10
T11
T7
T1
T12
TP1
L1
3
7
4
8
11
15
12
16
19
20
23
27
24
28
GENERATOR
F+ F-
GROUND
TO
FRAME
(3) JUMMPER
WIRES ON PHASE
SWITCH 15-20, 12-17,
10-21
T2
L2
TP3
P2
P1
E1
E2
E3
F+
FA2
5 AMP FUSE
A1
ON REGULATOR VR1
VR2
50HZ
60HZ
48
T3
L3
PM500
VOLTAGE
REGULATOR
BN
BN/WT
BN/WT
BN
RD
BK
WT
BK
31 PIN
CONN 2
TO POWER ZONE PIN 39
RD
BK
TO POWER ZONE
AVR PINS
90471_ORG_08.29.13
AC WIRING DIAGRAM - 3 POSITION VOLTAGE SELECTOR SWITCH - MMG205
L2
L3
L0
120V
GFCI
RECPT
120V
GFCI
RECPT
MECHANICAL LUGS
L1
GND
120V
20A
BRKER
120V
20A
BRKER
GROUND
TO GEN FRAME
GRN/YEL
GRN/YEL
GRN/YEL
12VDC
SHUNT
MAIN
CIRCUIT
BREAKER
GRN/YEL
GRN/YEL
BRN
BRN
WIRES NOT USED IN
BUCK BOOST OPTION
BLK
BLK
240V 50A
BREAKER
BLK
240V 50A
BREAKER
BLK
240V 50A
BREAKER
BLK
240V
50A
RCPT.
BLK
TO POWER ZONE PIN 40
BLK
(T7)
PAIR BLK
BLK
PAIR BLK
(T9)
BLK
BLK
CT-3
BLK
CT-2
BLK
BLK
CT-1
240V
50A
RCPT.
BLK
LT BLU
LT BLU
LT BLU
LT BLU
LT BLU
PAIR BLK
(L0)
SEE DC WIRING DIAGRAM
FOR CT CONNECTIONS
240V
50A
RCPT.
BLK
L3
L0
L2
BLK
1
3
5
2
4
6
54
55
50
48
43
34
7
10
20
T3 T9
3
T7
T2
T11
T6
T10
T12
T5
T8
40
30
17
24
F+ F-
GROUND
TO
FRAME
T1 T4
2
16
L1
37
GENERATOR
(3) JUMMPERS ON
PHASE SWITCH 7-43,
30-43, 30-37
11
PM500
VOLTAGE
REGULATOR
P2
P1
E1
E2
E3
F+
FA2
5 AMP FUSE
A1
ON REGULATOR VR1
VR2
50HZ
60HZ
BN
BN/WT
BN/WT
BN
RD
BK
WT
BK
TO POWER ZONE PIN 39
31-PIN
CONN 2
RED
BLK
2
3
TO POWER ZONE
AVR PINS
90469_ORG_08.29.13
49
P2
P1
E1
E2
E3
F+
FA2
5 AMP FUSE
A1
ON REGULATOR VR1
VR2
50HZ
60HZ
RD
BK
WT
BK
BN
BN/WT
PM500
VOLTAGE
REGULATOR
TO POWER ZONE PIN 39
TO POWER ZONE
AVR PINS
BN/WT
BN
CT-1
29
2
3
RED
BLK
RD/BK
CT-2
BLK
TP1
TP2
(L0)
(T9)
BLK
BLK
(T7)
BLK
8
4
TP0
7
6
2
3
5
1
GROUND
TO GEN FRAME
12
11
10
9
16
15
14
13
20
19
18
17
24
23
22
21
TO POWER ZONE PIN 40
BLK
BLK
BLK
BLK
BLK
BLK
BRN
BRN
GRN/YEL 10GA
GRN/YEL 10GA
GRN/YEL 10GA
GRN/YEL 14GA
GRN/YEL 14GA
28
27
26
25
TP3A
32
31
30
29
BLK
X
Y
G
W
36
35
34
33
40
39
38
37
RED
BRN/WHT
YEL
BN/WT
ORG
BLK
50A
CIRCUIT
BREAKER
TP3
20 AMP
G.F.I.
OUTLET
BLU
3
BLU
28
T12
T3
T4
T6
T8
T2
T11
T7
T1
T9
T10
T5
Y
G
5
RED
8
31 POS CONN2
DEUTSCH PLUG
1
4 6
BLK
W
20 AMP
G.F.I.
OUTLET
7
2
Y
G
BRN
GN/YL
GROUND
TO
FRAME
BLU
BLU
20 AMP
90472_ORG_08.29.13
FF+
W
50A
CIRCUIT
BREAKER
X
VOLT REGULATION
RELAY
GENERATOR
50A
CIRCUIT
BREAKER
X
20 AMP
BLU
GND
BLK
12VDC
SHUNT
31 POS CONN2
DEUTSCH PLUG
RED
BLK
TO TB1 FUSED & SWITCHED
SEE DC PRINT
BLK
31 POS CONN2
DEUTSCH PLUG
BLK
CT-3
L3
BLK
CIRCUIT
BREAKER
L0
BLK
BLK
L2
BLK
MECHANICAL LUGS
BLK
50
L1
AC WIRING DIAGRAM - 4-POS. VOLT. SELECTOR SWITCH OPTION - MMG130D, MMG175
P2
P1
E1
E2
E3
F+
FA2
5 AMP FUSE
A1
ON REGULATOR VR1
VR2
50HZ
60HZ
RD
BK
WT
BK
BN
BN/WT
PM500
VOLTAGE
REGULATOR
12VDC
SHUNT
CT-1
TO POWER ZONE PIN 39
TO POWER ZONE
AVR PINS
BN/WT
BN
TO CONTROL
POWER SW
SEE DC PRINT
CIRCUIT
BREAKER
RD
BK
CT-3
3/0
CT-2
BLK
BLK
ORN
P
N
21 PIN
DEUTSCH PLUG
TP1
L0
4
61
19
52
(L0)
(T9)
(T7)
2
RD
BK
23
36
11
3/0
65
56
44
7
8
14
32
40
GROUND
TO GEN FRAME
16
33
70
48
1
57
60
6
68
41
26
BLK
BLK
BLK
BLK
BLK
BLK
BRN
BRN
GRN/YEL 10GA
GRN/YEL 10GA
GRN/YEL 10GA
GRN/YEL 14GA
GRN/YEL 14GA
X
Y
G
W
50A
CIRCUIT
BREAKER
BLK
T7
T8
T9
T4
T5
T6
T3
T2
T1
1
4 6
8
BLU
F+ F-
GENERATOR
BN/WT
BN
RD
3
BK
WT/BN
OR
YL
TO POWER ZONE PIN 40
20 AMP
G.F.I.
OUTLET
5
7
2
Y
G
W
20 AMP
G.F.I.
OUTLET
VOLT REGULATION
RELAY
GN
50A
CIRCUIT
BREAKER
X
20 AMP
BLK
GND
BLK
3/0
BLK
3/0
BLK
BLK
L3
Y
G
W
BLU
GROUND
TO
FRAME
50A
CIRCUIT
BREAKER
X
BLU
20 AMP
90470_ORG_08.29.13
BLU
L2
YEL
BLK
BLK
BLK
MECHANICAL LUGS
BLU
T10
T11
T12
BLK
L1
AC WIRING DIAGRAM - 4-POS. VOLT. SELECTOR SWITCH OPTION - MMG205
51
POWER
RELAY
33
X3
X1
BN
BK
H2
BN/WT
H3
L3
TO LUG
BLOCK
L0 GND
GROUND
M
21 PIN
DEUTSCH
CONN-2
OR
V
OR
BK
8
BN/WT
RD
YL
BK
T9
T7
RECONNECT
DOOR
USED ON
SOME
NON-POWER
ZONE
MODELS
34
33
40
GEN
E1
E2
E3
UP
CGND
DOWN
DROOP OFF
AUX +
AUX -
WT
WT
BK
BK
RD
21 POS
DEUTSCH
CONN-1
H1
SPLICE
SPLICE
OR
GN
WT
BK
RD
WT
BK
OR
6
7
31 POS
DEUTSCH
CONN-2
3
2
F+
FPOWER ZONE
ONLY
31 PIN
DEUTSCH
CONN-2
DVR
WIRE
TO
EDISON
PLUG
DOWN
NON-POWER
ZONE MODELS ONLY
E1
E1
P2
BR/WT
P1
3
POWER
ZONE
CONTROL
ONLY
LUG
DOOR
NON-POWER
ZONE
P2
BN/WT
POWER
ZONE
CONTROL
ONLY
LUG
DOOR
NON-POWER
ZONE
BR/WT
BN
ADJUSTMENT SWITCH
UP REMOTE VOLTAGE
POWER ZONE POS 38
POWER ZONE POS 37
N
P
21 PIN
DEUTSCH
CONN-1
H4
H2
H3
BN/WT
BN
GENERATOR
HEATER
V
B
R
GEN
6
NEUTRAL
BAR
T4
T3
T2
T1
OR
7
31 PIN
DEUTSCH
CONN-2
DEDICATED
240V GEN
USED ON
MMG235
AND
HIGHER
OR
L3
S
BN/WT
BN
L2
L2
T9
L0
L1
T7
V
USED ON
MMG185
AND
LOWER
POWER ZONE
CONTROL ONLY
39
R
21 POS
DEUTSCH
CONN-2
GROUND RING TO
GENERATOR BOX
BOLT
HEATER
3
4
DVR 2000E+
F+
F-
BN/WT
BR/WT
BN
HEATER
RECONNECT
DOOR
USED ON
SOME
NON-POWER
ZONE
MODELS
34
33
PMG
CIRCUIT
BREAKER
OR
B
USED ON
MMG235
AND
HIGHER
S
21 PIN
DEUTSCH
CONN-1
USED ON
MMG185
AND
LOWER
21 PIN
DEUTSCH
CONN-2
L1
BN/WT
BN
TO GEN VOLT L3 OR
TO GEN VOLT L1 BR
LUG
DOOR
NON-POWER
ZONE
GN/YL
TO T7
TO T7
TO T9
6
7
BN
POWER ZONE ONLY
15
6
31 PIN
DEUTSCH
CONN-2
31 PIN
DEUTSCH
CONN-2
B
USED ON
MMG235
AND
HIGHER
OR
5
BK
2
7
21 PIN
DEUTSCH
CONN-1
TO L0
WHT
VOLTAGE RELAY
TO 120V BREAKERS
BUCK TRANSFORMER
S
R
L2
NOTE: REPEAT ALT CAM LOCK FOR ADDITIONAL SETS.
L3
USED ON
MMG185
AND
LOWER
21 PIN
DEUTSCH
CONN-2
H4
ALT
CAM L1
LOCK
PANEL
GROUND
BN
BN
TO T8
(NOT USED IN POWER ZONE)
USED ON
SOME
NON-POWER
ZONE
MODELS
RECONNECT
DOOR
34
X2
L2
BUCK XFORMER
TO L0
H1
X4
PMG
RD
NC
7
8
6
NO
5
4
2
COM
BK
L1
TO LUG
BLOCK
L0 GND
1
3
CIRCUIT
BREAKER
L3
BK
L2
WT
BN/WT
BR/WT
40
39
E1
E1
P1
3
F+
F+
F-
T7
T9
(2.5K, 2 WATT)
VOLTAGE
ADJUSTMENT
SEE POWER
ZONE OPTION
N
P
OR
E2
VR2
VR1
VR1
7
VR2
6
E2
E3/4
T9
CONNECT TO CONN2 POS K OR
600V RELAY PIN4 WHEN EQUIPPED
CONNECT TO CONN2 POS L OR
600V RELAY PIN8 WHEN EQUIPPED
NOT CONNECTED TO
T7 & T9 FOR V-FLEX
CONNECT TO CONN2 POS K OR
600V RELAY PIN4 WHEN EQUIPPED
NOT CONNECTED TO
T9 FOR V-FLEX OR PM500
GEN
T7
F-
F+
E3
PM300 VOLTAGE
REGULATOR
4 6
E3
A1
5
7
2
28
D
OR
31 POS
DEUTSCH
CONN-2
21 POS
DEUTSCH
CONN-2
VOLT REGULATION
RELAY
TO GND BAR
NOT CONNECTED TO
T9 FOR V-FLEX OR PM500
8
GEN
T7
F-
CONNECT TO CONN2 POS K OR
600V RELAY PIN4 WHEN EQUIPPED
CONNECT TO CONN2 POS L OR
600V RELAY PIN8 WHEN EQUIPPED
NOT CONNECTED TO
T7 & T9 FOR V-FLEX
CONNECT TO CONN2 POS K OR
600V RELAY PIN4 WHEN EQUIPPED
1
T9
F+
A2
TO CONTACT ON
4 POS PHASE SWITCH
90415_S_02.19.14
PM500 VOLTAGE
REGULATOR (ALTERNATE)
POWER
37
ZONE
38 CONTROL
PMG
PMG
W/4 POS
PHASE SWITCH
PM500 VOLTAGE
REGULATOR (ALTERNATE)
V-FLEX ONLY
3
A2
PM300 VOLTAGE
REGULATOR
3
2
A1
POWER
37
ZONE
38 CONTROL
V-FLEX ONLY
31 POS
DEUTSCH
CONN-2
E3/4
6
3
2
31 PIN
DEUTSCH
CONN-2
7
21 POS
DEUTSCH
CONN-1
F-
F-
F-
F+
F+
T7
T9
OR
(2.5K, 2 WATT)
VOLTAGE
ADJUSTMENT
SEE POWER
ZONE OPTION
N
P
21 PIN
DEUTSCH
CONN-1
BK
L1
CAM
LOCK
PANEL
WT
BN/WT
BN
BN
RD
RD
BN
BN
BK
BK
BK
BK/WT
BK
TO L2
PMG
BK
BN/WT
40
39
BR/WT
BK
WT
WT
BN
WT
WT
BK
BN/WT
OR
TO L3
BN
YL
BK
GN/YL
52
RD
CAM LOCKS
AC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT
RD
IGNITION
RD
RD
M
L
K
E
J
R
P
TO
GND
BAR
RD/VI
RD
RD
21 PIN
CONN1
G
C
W
B
A
D
T
BK
OR
BK
CLR
SHLD
RD
RD
RD/VI
RD/VI
RD/VI
RD/VI
1 20A
RD
2 15A
RD
3 20A
4 SPARE
FUSE
BLOCK
RD
RD/BK
TB1
RD/WT
RD/WT
RD/BK
RD/BK
RD/BK
RD/VI
RD/WT
RD/WT
RD/BK
CONTROL
POWER
SWITCH
RD/VI
30
87
1
2
87
86
85
87
52
51
RD
55
54
16
5
4
U
L1
22
OPTIONAL
FAN
CLUTCH
OPTIONAL
HEATED
FUEL
FILTER
25
24
21
17
1
FUEL
LEVEL
41
42
6
15
4
5
REMOTE
START
CONTACT
NO
RECONNECT
DOOR
SWITCH
(HELD
CLOSED
NORMALLY)
C
2
1
TB3
24
22
MPU
23
MODULE 8700
SCR
B
C D E
F
61 62 63 64 65
CLOSE
GEN
OUTPUT
D
SHUNT TRIP
8
19
18
N
TO
GND
BAR
WT
A
60
46
L0
45
L3
44
L2
YL
WT
V
W
L2
L3
GEN VOLTS
V1
43
20
RD/BK
VI/YL
VI/YL
SERVICE
SWITCH
L1
10
NC
E-STOP
SWITCH
21
9
3
B
A
FLEXIBLE IF
J1939 IS USED
GEN CURRENT
RS232
TO
GND
BAR
GY/OR
53
TO
GND
BAR
CT1 CT2 CT3 CT4 COM
L1S1 L2S1 L3S1 NS1
START
GY/YL
BK/WT
85
86
TO
GND BK/WT
BAR
30
TO
GND
BAR
CLUTCH
FAN
RD/WT
HEATED
FILTER
RD/VI
SCR
B
A
BATTERY
BK/WT
85
86
SHLD
TO
GND
BAR
30
BK
CLR
RS485
TO DISPLAY
RS485
RD
1. TO ADD OPTIONAL REMOTE ANNUNCIATOR (COMMUNICATIONS)
FOR ATT GENERAC USE ANALOG EXPANSION MODULE.
2. TO ADD OPTIONAL ANALOG GAUGES USE ANALOG EXPANSION MODULE.
NOTES:
STARTER
12 V
BATTERY
ALT
ENGINE
GND
+
30A
V
CAN-HIGH
S
BK
U
CAN-LOW
N
OR
F
CAN-SHIELD
RD/VI
RD
TO
GND
BAR
RD/WT
BK/WT
RD
FUEL
BATT
RD
FU&SW
FUSED
+VE
TO DISPLAY
POWER
RD/YL
H
X
RD
87A
87A
GN/YL
RD/VI
RD/VI
87A
TO
GND
BAR
VI/YL
VI/YL
GY/OR
GY/OR
-VE
GN/YL
WT
CT-2
BN/WT
GN/YL
WT CT-3
YL/WT
CT-1
WT
OR/WT
RD/VI
FUEL
RD/VI
BK/WT
BK/WT
BK/WT
GN/YL
CRANK
RD/YL
BK
WATER TEMP
RD/BK
RD/BK
VI/YL
WT/VI
WT/VI
OIL PRESSURE
BK/WT
BK/WT
SHUNT
RD
WT/VI
FUEL LEVEL (FLEXIBLE)
WT
AUX FUEL TANK SENDER
BL
COMMON GROUND
BK/WT
BK/WT
OPTIONAL
INTERIOR
LIGHT
23
22
TO
GND
BAR
16
B
40
OUTPUT
C
39
H
67
2
3
TO
GEN FIELD
29
-
28
+
K
70
LEAK
DETECT
OPTIONAL
OPTIONAL
FUEL
XFER
PUMP
14
E
8
7
57
S2
S1
L1 LOAD
CURRENT
8660 ONLY
56
J
13
H I
11 12
6
12
31
30
405 &
465
NEUTRAL
SENSING
CT
7
11
R
L1
48
49
38
37
AVR
O/P
B
A
29
28
15
N.O.
4 POS
PHASE
SWITCH
31 PIN
CONN 2
L
26
H
25
ENGINE ECU
SCR
27
90438_E_02.12.14
T8
USB
L
32
PROGRAMMING
PORT
TO VOLTAGE
REGULATOR
SEE AC PRINT
36
18
35
H
USB HOST
31
MSC
33
SCR
N
19
34
GOVERNOR
O/P
B
A
RJ45
ETHERNET
S
T
L2
L3
BUS VOLTS
V2
47
50
FOR VREG CUTOUT
RECONNECT/LUG DOOR
TO EXPANSION MODULES
G
10
OPTIONAL
PMG
F
9
+VE 6 FET OUTPUTS
13
J
69
30
SCR
27
I
68
TO VOLTAGE REGULATOR SEE AC PRINT
TO 3 POS LUG BLOCK T7
OR 31 POS DEUTSCH PIN 6 FOR PMG
SEE AC PRINT
26
TO
VOLTAGE
REGULATOR
(HELD
CLOSED
NORMALLY)
NO
G
66
11 INPUTS
LUG
DOOR
LOW
COOLANT
A
TO
GND
BAR
C
TO
GND
BAR
17
FORCE REGEN
YL
CHRG ALT
OR
GY
GY
BK/WT
BK/WT
BK/WT
RD/BK
REMOTE START
RECONNECT DOOR
GY
RD/WT
RD/WT
OPTIONAL
GY/OR
BK/WT
BK/WT
BK/WT
LOW COOLANT
GY/BK
GY/BK
INHIBIT REGEN
GY/BL
INHIBIT REGEN SWITCH
INHIBIT
FUEL TRANSFER
RD/BK
WT/RD
GY/GN
BN/WT
FUEL XFER ENABLE
CLR
WT/RD
BK/WT
GY/BK
MANUAL
BN/WT
OIL LEVEL
BK
LOAD SHED
BK/WT
AUTO
ALARM
OR/BK
SHLD
BK/WT
BK/WT
LUG DOOR
OR/WT
RD F+
RD
GEN
F+
BK/WT
BK/WT
LEAK DETECT
WT/RD
F-
BK
BK
GEN
F-
GY/YL
SPARE
RD/VI
PWR
OPTIONAL
BK/WT
GND
BK
FAN CLUTCH
OPTIONAL
BN
BN
BN/WT
RED BEACON
OR/WT
OPTIONAL
BN/WT
OR/WT
OR/WT
RED
BEACON
BK/WT
BK/WT
SPARE
BL
BK
OR/YL
OR/YL
AMBER
BEACON
AMB BEACON
WT/BL
WT/BL
BL
OPTIONAL-DVR
YL
YL
OR/YL
OR/BK
OR/BK
ALARM
WT
TO VREG RELAY PIN 7
RD
RD
RD/BK
RD/BK
CLR
MAIN
BREAKER
DC WIRING DIAGRAM
53
85
30
87A
87
86
+12V
21 PIN
X
W
MAY NOT NEED RELAY IF
CONTACTOR CURRENT
REQUIREMENTS ARE LOW.
LOAD
SHED
NOT THRU 31 PIN CONN.
USE ROMEX CONNECTOR.
TO POWER ZONE
CONTROL PIN 69
OR
TO TB1 (BATT)
RD
BK/WT
85
15A
GRY/VIO
87
30
87A
86
RD/VI
85
PIN
LOCATION
30
RD/WT
MTB
8
300 OHM
1.3K OHM
T
CHARGE
MODULE
TO GND
BAR
BK/WT
.
.
BK/WT
RD/OR
P
N
S
R
21 PIN
21 PIN
RD/YL
JD
CONN-2
DEUTSCH
2A FUSE
.
.
FUEL
TRANSFER
PUMP
22
23
31 PIN
DEUTSCH
CONN-2
RD/BK
BK/WT
BLK
RED
12 V
BATTERY
INTERIOR
LIGHT 1
FUEL
TRANSFER
PUMP PZ
1
2
RD/BK
CONN-2
DEUTSCH
14
13
31 PIN
RD/WT
BI4
LEAK
DETECT
?
MAY
VARY
31 PIN
CONN-2 CONN-1
DEUTSCH DEUTSCH
21 PIN
NC
AUTOMATIC IDLE
87A
85
RD/VI
22
ESTOP
FILTER
HEATER
HEATED
FUEL
FILTER
MMG 405
& 465 ONLY
1
OR
31 PIN
CONN-2
MTB
RD/BK
BK/WT
21 PIN
CONN-2
24
25
OR
C
A
SOLAR BATTERY
CHARGER
TO GND
BAR
TB1
86
87
BK/WT
TO GND
BAR
RD/VI
TO PZ CONTROL PIN 9
FUEL XFER
RELAY
86
HIGH IDLE
RELAY
BK/YL
SOLAR
PANEL
BO6
BO3
BO4
BO5
30
87A
87
FUEL HEAT
RELAY
MTB
FLOAT
RD SWITCH RD SPLICE
RD/BK
TO GND
BAR
BK/WT
4 PIN PLUG
BINARY OUT
SPLICE
BLK/WHT
FAN
CLUTCH
INTERIOR
LIGHT 1
FAN
CLUTCH
BK/WT
GY/OR
RD/BK
BK
INTERIOR
LIGHT 2
PANEL LIGHT
FUEL TRANSFER
ENABLE SW
31 PIN
21
20
DEUTSCH
CONN-2
H
J
21 PIN
DEUTSCH
CONN-2
TO GND
BAR
TO
GY/OR CONT
BO7
LOAD SHED
RELAY
CONTACTOR
FOR LOAD
TO GND
BAR
30
85
GY/OR
87A
87
RD/BK
LIGHT SWITCH
RD/BK
BK
MTB
10 OR 12 POS
FUSED POWER
7
FLIPHOOD
4 DOOR
10
25A FUSE
TB1
NO
-
COM
NO
-
2
1
BK
COM
NO
-
4
1
2
7
6
8
WT
REMOTE COMMUNICATION
RELAY BOARD
2 3 4 5
COM
+
BO6
BO3
BO4
BO5
85
8
MTB
30
87A
87
RD/WT
RD/BK
86
BK/WT
BATTERY
DISCONNECT
E
G
21 PIN
?
21 PIN
.
.
1
2
.
.
?
MAY
VARY
31 PIN
FUEL
TRANSFER
PUMP
TO POWER ZONE
CONTROL PIN 68
ENGINE
HEATER
90416_L_02.04.14
WT
GN
BK
LOW OIL
LEVEL
ENGINE
HEATER
BLK
FUEL
TRANSFER
PUMP COMAP
CONN-2
DEUTSCH
EDISON PLUG
RD/VI
TO GND
BAR
BK/WT
TO GND
BAR
12 V
BATTERY
BATTERY
DISCONNECT
12 V
BATTERY
BATTERY
CHARGER
16/3
BATTERY
CHARGER
BLU
YEL/GRN
BRN
EDISON PLUG
CONN-2 CONN-1
DEUTSCH DEUTSCH
FUEL XFER
RELAY
BK/WT
RD/WT
RD/VI
FUEL TRANSFER
ENABLE SW
RD SWITCH RD SPLICE
GY/VI
GY/VI
INTERIOR
CABINET
LIGHT PZ
CONTROL
PANEL
LIGHT PZ
OPEN
FUEL XFER
OPEN
OPEN
LOCATION
4 PIN PLUG (BINARY OUTPUTS)
PLUG LOCATION
PIN
BI1
PIN
LOCATION
BI2
BI3
BI4
BI5
BI6
BOTTOM
3
+
REMOTE
COMMUNICATION
GY/OR
REMOTE START
LOW COOLANT OPTION
RECONNECT DOOR
OPEN
FUEL XFER ENABLE
PLUG LOCATION
BOTTOM
NO
-
12 11 10 9
COM
+
REMOTE
START
1
+
E STOP
INTERIOR
LIGHT 2
RD/BK
BK
BK
BK
BK
RD
6 PIN PLUG (BINARY INPUTS)
BI2
BO7
BO6
BO5
BO4
+
D+
PLUG
LABEL
RELAY BOARD
WT 6
PANEL LIGHT
DOOR SWITCH
MTB PIN 1
(FUEL)
OR
ESTOP ON UNITS UP TO MMG55
86
FAN
CLUTCH
RELAY
RD/VI
LIGHT ENABLE
SWITCH
INTERIOR
CABINET
LIGHT
COMAP
BK/WT
WT 4
MAIN POWER
SWITCH
BATT
WT 8
CONTROL
PANEL
LIGHT
COMAP
GY/VI
WT 12
MTB
10 OR 12 POS
FUSED POWER
RD/VI
FU&SW
BLK
RD/WT
FU&SW
FUSED
+
BATT
+
FUSED
-
WT
RED
+
54
-
7
DC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT
TO CONTROL BOX
L3
L2
L1
LO
L9
TO CONTROL BOX
L3
L2
L1
LO
208/120V 3PH
LOW WYE
TO GENERATOR
L9
L7
TO CONTROL BOX
L3
L1
LO
TO CONTROL BOX
L3
L1
LO
240/120V 1 PH
LOW ZIG ZAG
TO GENERATOR
TO GENERATOR
NOTE:
1. CABLES TO CONTROL BOX MAY CONTAIN 1, 2 OR 3 WIRES DEPENDING ON THE MODEL AND VOLTAGE.
2. APPLIES TO ALL 12 LEAD GENERATORS TO BE HARD WIRED IN GEN BOX.
TO GENERATOR
T4
T5
T6
T10
T11
T12
T3
T9
480/240V 1 PH
HIGH ZIG ZAG
L9
T2
T6
T8
T12
T10
T11
T12
T3
T9
T6
T8
T5
T2
T1
T7
T4
T2
T8
T10
T4
T5
T10
T11
T3
T9
L7
T1
T7
T11
T3
T9
T6
T1
T4
T7
T12
T5
T8
T2
L7
T1
T7
TO CONTROL BOX
L3
L2
L1
LO
240/120V 3PH
HIGH DELTA
L9
TO CONTROL BOX
L3
L2
L1
LO
120V 3PH
LOW DELTA
TO GENERATOR
T9
T6
T3
T5
T8
T11
T2
L9
L7
T10
T12
T7
T4
T1
L7
90302_A_11.06.12
TO GENERATOR
T3
T5
T9
T11
T2
T4
T8
T10
T1
T6
T7
T12
480/277V 3PH
HIGH WYE
WIRING BLOCK DIAGRAM - DEDICATED 12 LEAD GENERATORS OPTION
55
YL
GN
BN
WT
TRAILER
PLUG
BK
BK
AMBER
MARKER
LAMP
RED
MARKER
LAMP
FENDER
BK
AMBER
MARKER
LAMP
BK
BN
BK
WT
BK
BN
BN
BK
WT
WT
BK
BN
BN
WT
BN
RED
MARKER
LAMP
BK
BK
BK
RD
WT
BK
60386_A_02.14.14
STOP-TURN
SIGNAL LAMP
RIGHT
PLATE
LAMP
BK
BK
RD
WT
STOP-TURN
SIGNAL LAMP
RIGHT
IDENTIFICATION
LIGHT BAR
BK
BK
WT
BN
BK
BK
WT
BK
WT
WT
RED
MARKER
LAMP
WT
BK
RED
MARKER
LAMP
BN
BN
AMBER
MARKER
LAMP
GN
BN
AMBER
MARKER
LAMP
WT
YL
56
WT
FENDER
TRAILER LIGHTS WIRING DIAGRAM
WT
BL
SPLICE
BK
SWITCH
BREAKAWAY
BL
SPLICE
BK
BL
BATTERY
WT
FRAME GND
BL
WT
SPLICE
SPLICE
SPLICE
TRI-AXLE
SPLICE
TANDEM AXLE
BL
WT
90286_E_03.18.14
SINGLE AXLE
BL
WT
BRAKE
BRAKE
SPLICE
SPLICE
BRAKE
SPLICE
BRAKE
SPLICE
SPLICE
SPLICE
BRAKE
SPLICE
SPLICE
BRAKE
WIRING HARNESS - ELECTRIC BRAKE OPTION
57
SERVICE LOG
OIL GRADE AND TYPE: ____________________________ BRAND:___________________________________
COOLANT MIXTURE: ______________________________ BRAND:___________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
58
REV: B
PART NO: 33722
05.01.14