DIESEL GENERATORS MMG 125 • MMG 155 MMG 180 • MMG 230 ww w m -p -ll c co m 23 0 OPERATING MANUAL
INTRODUCTION This manual provides information and procedures to safely operate and maintain the engine and generator. For your own safety and protection from physical injury, carefully read, understand, and observe the safety instructions described in this manual. The information contained in this manual was based on machines in production at the time of publication. Magnum Products LLC reserves the right to change any portion of this information without notice.
TABLE OF CONTENTS Page INTRODUCTION ........................................................................................................................... 2 TABLE OF CONTENTS ................................................................................................................ 3 SAFETY NOTES .......................................................................................................................... 4 OPERATING SAFETY ..............................................................
SAFETY NOTES This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. This manual contains DANGERS, WARNINGS, CAUTIONS, NOTICES and NOTES which must be followed to prevent the possibility of improper service, damage to the equipment, personal injury or death.
ENGINE SAFETY Internal combustion engines present special hazards during operation and fueling! Failure to follow the safety guidelines described below could result in severe injury or death. Read and follow all safety warnings described in the Engine Operator's Manual. A copy of this manual was supplied with the unit when it was shipped from the factory. • DO NOT run the engine indoors or in an area with poor ventilation unless exhaust hoses are used.
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.
UNIT SERIAL NUMBER LOCATIONS Refer to the locations illustrated below to find the unit ID tag, V.I.N. tag and trailer ID tag on your unit. Important information, such as the unit serial number, model number and Vehicle Identification Number (V.I.N.) for your trailer are found on these tags. Record the information from these tags, so it is available if the tags are lost or damaged. When ordering parts or requesting technical service information, you may be asked to specify this information.
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. Below is a summary of the intended meanings for the symbols used on the decals. 8 Safety alert symbol; Used to alert you to potential personal injury hazards. Asphyxiation hazard; Operate in well ventilated area.
SPECIFICATIONS Read this manual carefully before attempting to use this generator. The potential for property damage, personal injury or death exists if this equipment is misused or installed incorrectly. Read all of the manuals included with this unit. Each manual details specific information regarding items such as set up, use and service requirements. Specifications are subject to change without notice. MAGNUM MODEL MMG 125 MMG 125 Super Start (SS) Engine Make/Brand ...................................
SPECIFICATIONS Read this manual carefully before attempting to use this generator. The potential for property damage, personal injury or death exists if this equipment is misused or installed incorrectly. Read all of the manuals included with this unit. Each manual details specific information regarding items such as set up, use and service requirements. Specifications are subject to change without notice. MAGNUM MODEL MMG 155 MMG 155 Super Start (SS) Engine Make/Brand ...................................
SPECIFICATIONS Read this manual carefully before attempting to use this generator. The potential for property damage, personal injury or death exists if this equipment is misused or installed incorrectly. Read all of the manuals included with this unit. Each manual details specific information regarding items such as set up, use and service requirements. Specifications are subject to change without notice. MAGNUM MODEL MMG 180 MMG 180 Super Start (SS) Engine Make/Brand ...................................
SPECIFICATIONS Read this manual carefully before attempting to use this generator. The potential for property damage, personal injury or death exists if this equipment is misused or installed incorrectly. Read all of the manuals included with this unit. Each manual details specific information regarding items such as set up, use and service requirements. Specifications are subject to change without notice. MAGNUM MODEL MMG 230 MMG 230 Super Start (SS) Engine Make/Brand ...................................
UNIT DIMENSIONS Read this manual carefully before attempting to use this generator. The potential for property damage, personal injury or death exists if this equipment is misused or installed incorrectly. Read all of the manuals included with this unit. Each manual details specific information regarding items such as set up, use and service requirements. Specifications are subject to change without notice. Dimensions (L x W x H) MMG 125, 155 MMG 180, 230 Skid Mounted in (m) .............................
SERVICE LOCATIONS 14
MAIN CONTROL PANEL FEATURES 1 2 3 15 4 5 14 6 13 7 12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 9 10 11 8 DOCUMENT HOLDER AIR FILTER METER: This gauge shows the condition of the air filter when the engine is running. MAGNUM DIGITAL CONTROLLER (MDC): See pages 16 - 17 for additional information. AUXILIARY LIGHT SWITCHES: These switches operate the optional control panel and interior lights.
MAGNUM DIGITAL CONTROLLER (MDC) The Magnum Digital Controller (MDC) is an enhanced digital generator controller used to start, stop and monitor the operation of the generator and the engine. The controller constantly monitors vital generator and engine functions for a number of pre-programmed alarm and fault conditions.
• • “ALARM CANCEL” Button When an alarm is activated, either visually or audibly, press this button to silence or cancel the alarm. “FAULT RESET” Button Press this button to clear the fault from the LCD window after the fault has been corrected. Press “FAULT RESET” and “ENTER” to clear the John Deere ECU Alarm List Codes. 3. The Liquid Crystal Display (LCD) • This window will toggle between the Generator Display Screen and the Engine Display Screen upon startup of the unit.
ENGINE MONITORING Engine information is shown on the Liquid Crystal Display (LCD) window in a toggling manner with the Generator information after the first 60 seconds of operation and then every 5 seconds thereafter. The engine display screen will show oil pressure, engine coolant temperature, fuel level and battery voltage. • Oil Press: • Eng Temp: • Fuel Level: • Vbat: Displays engine oil pressure. The display registers oil pressure between 0-100 psi.
The history of alarms or codes of the unit are saved in the digital controller. The most recent alarm or code is the first to be listed, with the time/date of the alarm or code at the bottom of the screen. The controller stores up to 118 codes. When full, the controller will automatically remove the oldest file. These codes will not be lost when the control power toggle switch is powered off.
GENERATOR START UP Before starting the generator, carefully read over the pre-start check list. Make sure that all of the items are checked before trying to start the generator. This check list applies to both manual and remote starting of the generator. PRE- START CHECK LIST Make sure the control ON/OFF toggle switch is in the OFF “O” position. Make sure that the circuit breakers (main and convenience) are switched OFF “O”.
4. Press the green “ENGINE START” button. The Prestart (Preheat) screen will be displayed (if equipped) and a countdown will begin from 20 seconds to 0. 5. The Starting screen will be displayed. The engine will crank and start running. 6. The Running screen will display. Note: It may take a few seconds for the engine to run smoothly and reach its governed operating speed. The 45 second “SENSING” time delay will start to count down. 7.
10. Once the engine starts it will immediately begin speeding up to a constant 1800 rpm. On units with isochronous engine governing, the engine may hunt or change speeds until operating temperature is reached. After a few minutes of operation, the engine will be warmed up and the LCD window will show engine and generator operating parameters. Temperature will be shown as “0” until the engine temperature is approximately 100° F. 11.
MAGNUM DIGITAL CONTROLLER (MDC) INFORMATION DISPLAYS, FUNCTIONS AND RESET The Magnum Digital Controller (MDC) constantly monitors vital generator and engine functions for a number of operation, alarm and fault conditions. When a fault condition occurs, the engine will shut down automatically and the Liquid Crystal Display (LCD) window will show the fault that has caused the shut down. To resume operation, the fault condition must be resolved.
MAGNUM DIGITAL CONTROLLER (MDC) - LIST OF POSSIBLE ALARMS/DESCRIPTIONS Shut down and warning fault conditions and the displayed message are described in the following table: No. Events Specification Protection Type Information on Binary Output Available Description SD YES Shutdown alarm configurable on the input of IG-IOM/IGS-PTM. WRN YES SD YES Warning alarm configurable on the input of IG-IOM/IGS-PTM.
28 Vgen unbal 29 Wrn ECU Alarm SD WRN NO NO 30 Wrn RA15 fail WRN NO 31 WrnServiceTime WRN NO The generator voltage is unbalanced more than the value of Volt unbal setpoint. ECU alarm list is not empty. Warning alarm in case of lost connection to IGL-RA15 module. The period for servicing is set by the NextServTime setpoint. The protection comes active if the running hours of the engine reach this value.
MAGNUM DIGITAL CONTROLLER (MDC) – HISTORY The Magnum Digital Controller (MDC) controller stores a record of each important event into the history file of the controller. The history file seats 118 records. When the history file is full, the oldest records are removed. No.
RESETTING OF THE “TIME TO SERVICE” REMINDER The Magnum Digital Controller (MDC) will display the message “ WrnServiceTime” when the unit is due for maintenance or service. The maintenance or service interval is set at 250 hours of engine running time. Once the unit has been serviced, the “ServiceTime” reminder needs to be reset to the 250 hour interval. The following procedure demonstrates how to reset the running hours to 250: 1.
HIGH COOLANT TEMPERATURE SHUTDOWN 1. Check the coolant level in the overflow jug. 2. Restart the engine and read the coolant temperature to verify High Coolant Temperature Shutdown. Stop the engine immediately if the coolant temperature is 230°F 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.
GENERATOR OUTPUT CONNECTION LUGS The generator is equipped with connection lugs behind the lug door next to the customer convenience outlets. The lugs provide connection points for attachment of external loads to the generator. A large decal on the inside of the connection lug door details the proper connections for selected voltages. WARNING It is HIGHLY RECOMMENDED that only a trained and licensed electrician perform any wiring and related connections to the generator.
VOLTAGE SELECTOR SWITCH (MMG 125-155-180) The voltage selector switch is located on a panel attached to the generator behind the door located next to the fuel tank filler. The selector switch is a three position switch that mechanically changes the connections between the generator output leads and the connection lugs on the main control panel. Voltage ranges are selected by rotating the handle on the switch to the desired voltage.
4-POSITION VOLTAGE SELECTOR SWITCH (OPTIONAL) The optional four position voltage selector switch is located on a panel attached to the generator behind the door located next to the fuel tank filler. The voltage selector is a four position switch that mechanically changes the connections between the generator output leads and the connection lugs on the main control panel. Voltage ranges are selected by rotating the handle on the switch to the desired voltage.
CHANGING OUTPUT VOLTAGE (MMG 230 ONLY) The output voltage can be changed by moving the shorting (link) board in the generator reconnect box. The reconnect box is located on the top of the generator. Before attempting to change the output voltage, shut the generator down and make sure that the main circuit breaker and the control power switch are in the off “O” position. WARNING Never attempt to change the voltage while the engine is running.
EMERGENCY STOP SWITCH ER GEN Y 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 E The generator is equipped with one emergency stop switch, located on the right rear corner of the unit next to the control door.
CUSTOMER CONVENIENCE OUTLETS The generator is equipped with five convenience outlets. The large outlets are 240/120 VAC twist-lock receptacles rated at 50 A each. The smaller outlets are 120 VAC duplex receptacles rated at 20 A each with ground fault interrupt (GFCI) protection. These receptacles are not routed through the main circuit breaker. Each receptacle has its own circuit breaker, located directly above or next to the outlet. Each breaker is sized to the maximum rating of the corresponding outlet.
REMOTE START TERMINAL BLOCK The remote start terminal block is located just under the two 120V duplex convenience outlets. It provides a connection for installation of a remote start switch which will allow the generator to be started by a remote dry-contact closure switch. Before pressing the “AUTO” button (or moving the toggle switch to the REMOTE START position on analog units), verify that the contacts on any remote switch linked to the generator are OPEN.
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 generator to a power supply normally serviced by a utility company, notify the utility company and check local and state regulations. Familiarize yourself with all instructions and warning labels supplied with the switch.
DAILY MAINTENANCE CHECKS Check the engine oil level daily before starting engine. DO NOT start the generator if the oil level is below the ADD mark on the dipstick. The normal operating level for the engine oil is anywhere in the crosshatch pattern between the FULL and ADD markings. Add oil to the engine only if the level is below the ADD mark on the bottom of the crosshatch pattern. DO NOT OVERFILL the crankcase.
TOWING THE TRAILER 1. 2. 3. 4. 5. 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. Release the jack locking pin and rotate the jack into the travel position. Make sure the locking pin snaps into place. Connect any trailer wiring to the tow vehicle. Check for proper operation of the stop and signal lights. Make sure all doors are closed and secure. Check for proper inflation of the trailer tires.
WHT WHT X2 X4 H4 H2 X1 X3 BUCK XFORMER H1 H3 RED BLK COM NO NC 2 7 5 8 BRN/WHT BLK BLK 4 AMP FUSE ON REGULATOR 6 4 50HZ 60HZ BLK BRN BRN/WHT RED F+ BLK FWHT SE350 VOLTAGE REGULATOR 3 F+ F7 12 MAIN CIRCUIT BREAKER SEE DC WIRING DIAGRAM FOR CT CONNECTIONS 6 VOLTAGE SENSING RELAY QTY 2 BRN RELAY BLK WHT BRN/WHT 11 LUG DOOR SAFETY SWITCH NO 12VDC SHUNT BUCK BOOST OPTION L3 CT-3 L2 CT-2 BLK CT-1 BLK L0 (2.
X2 X4 H4 H2 X1 X3 BUCK XFORMER H1 H3 RED 10GA NO NC BLK 14GA 2 7 5 8 6 VOLTAGE RELAY BLK 14GA 4 AMP FUSE ON REGULATOR 6 4 50HZ 60HZ 3 F+ F7 BLK BRN BRN/WHT BLK F+ BLK FWHT SE350 VOLTAGE REGULATOR TO LUG DOOR SW SEE DC PRINT TO 21 POS PLUG SEE DC PRINT BLK 10GA COM RELAY BLK 10GA WHT 10GA WHT 14GA B B RECONNECT DOOR SAFETY SWITCH 480V SHORT 208V SHORT CIRCUIT BREAKER 800A T8 T5 T7 T4 (2.
RPM GND MAG REF FUEL IN L2 L3 N PHASE B VOLTAGE PHASE C VOLTAGE NEUTRAL L2 L3 COM PHASE C CURRENT PHASE GND BO6 BO7 41 L COM ECU L ECU COM *NOT REQUIRED WITH JOHN DEERE ECU ENGINE H PIN LOCATION ECU H PLUG LOCATION LEFT SIDE 3 PIN PLUG BI1 BI2 BI3 BI4 BI5 BI6 BI7 REMOTE START LOW COOLANT OPTION OPEN OPEN OPEN OPEN PIN LOCATION E STOP PLUG LOCATION BOTTOM GY/BK GY/OR BLK Shield not connected Cut back and Tape 1 TB 2 WHT WHT WHT CT-2 CT-1 CT-3 REMOTE START CONTACTS RD/W
RPM GND FUEL IN L2 L3 N PHASE B VOLTAGE PHASE C VOLTAGE NEUTRAL L3 COM PHASE C CURRENT PHASE GND D+ D+ RD/VI BO6 BO7 H L COM ECU H ECU L ECU COM *NOT REQUIRED WITH JOHN DEERE ECU ENGINE PIN LOCATION PLUG LOCATION LEFT SIDE 3 PIN PLUG BI1 BI2 BI3 BI4 BI5 BI6 E STOP PIN LOCATION REMOTE START LOW COOLANT OPTION RECONNECT DOOR OPEN OPEN PLUG LOCATION BOTTOM TB 2 1 CT-2 WHT WHT REMOTE START CONTACTS BLK CT-1 CT-3 WHT RD/WT CONTROL POWER SWITCH Shield not connected Cut back a
WHT WHT WHT RED H4 H2 X2 X4 X1 X3 BUCK XFORMER H1 H3 NC NO BLK COM RELAY BLK L2 L3 L2 L3 L1 N 5 L1 COM 2 7 8 BLK CT1 CT2 CT COMMON CT3 6 VOLTAGE RELAY 4 AMP FUSE ON REGULATOR 6 4 50HZ 60HZ 3 F+ F7 12VDC SHUNT BRN/WHT BLK F+ BLK FWHT BLK BRN NO 23 12 24 CIRCUIT BREAKER SE350 VOLTAGE REGULATOR CT-1 BR/WT CT-3 CT-2 BRN/WHT YL/WT GN/YL OR/WT BRN YEL WHT ORN BRN/WHT 11 LUG DOOR SAFETY SWITCH NC L3 CT-3 CT-2 6GA CT-1 BLK MECHANICAL LUGS L2 6GA BLK L
X2 X4 H4 H2 X1 X3 BUCK XFORMER H1 H3 RED 10GA WHT 14GA WHT 10GA NO NC BLK 14GA 5 8 6 BLK 14GA 6 4 50HZ 60HZ 3 F+ F7 BLK BRN BRN/WHT RED F+ BLK FWHT SE350 VOLTAGE REGULATOR 2 7 VOLTAGE RELAY 4 AMP FUSE ON REGULATOR BLK 10GA COM RELAY BLK 10GA NO TO PLUG2 POS X SEE DC PRINT CIRCUIT BREAKER 800A (2.
TRAILER LIGHTS WIRING DIAGRAM 45
NOTES: 46
SERVICE LOG OIL GRADE AND TYPE: COOLANT MIXTURE: BRAND: BRAND: 47
REV: J PART NO: 22070 10.20.
