POWER PRODUCTS LLC DIESEL GENERATOR MMG130D • MMG175 • MMG205 With TM Controller 175 00382 OPERATING MANUAL Parts manuals available online! www.m-p-llc.
INTRODUCTION This manual provides information and procedures to safely operate and maintain the Magnum Power Products LLC unit. For your own safety and protection from physical injury, carefully read, understand, and observe the safety instructions described in this manual. Keep a copy of this manual with the unit at all times. Additional copies are available from Magnum Power Products LLC, or can be found at www.m-p-llc.com.
TABLE OF CONTENTS Page INTRODUCTION ................................................................................................................................ 2 SAFETY NOTES ................................................................................................................................ 6 OPERATING SAFETY ....................................................................................................................... 6 ENGINE SAFETY.................................................
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 ....................................
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SAFETY NOTES This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. This manual contains DANGERS, WARNINGS, CAUTIONS, NOTICES and NOTES which must be followed to prevent the possibility of improper service, damage to the equipment, personal injury or death.
• 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.
TOWING SAFETY Towing a trailer requires care. Both the trailer and vehicle must be in good condition and securely fastened to each other to reduce the possibility of an accident. Also, some states require that large trailers be registered and licensed. Contact your local Department of Transportation office to check on license requirements for your particular unit. • Check that the hitch and coupling on the towing vehicle are rated equal to, or greater than, the trailer's Gross Vehicle Weight Rating (GVWR).
SAFETY SYMBOL SUMMARY This equipment has been supplied with numerous safety and operating decals. These decals provide important operating instructions and warn of dangers and hazards. Replace any missing or hard-to-read decals and use care when washing or cleaning the unit. Decal placement and part numbers can be found in the parts manual. Below is a summary of the intended meanings for the symbols used on the decals. Safety alert symbol; used to alert you to potential personal injury hazards.
SPECIFICATIONS - MMG130D MAGNUM MODEL MMG130D MMG130D Super Start Engine Make/Brand...................................................................... John Deere ...................................John Deere Model ............................................................................... PE4045HFG93..............................PE4045HFG93 EPA Tier ........................................................................... 4i ...................................................
SPECIFICATIONS - MMG175 MAGNUM MODEL MMG175 MMG175 Super Start Engine Make/Brand...................................................................... John Deere ...................................John Deere Model ............................................................................... PE6068HFG94..............................PE6068HFG94 EPA Tier ........................................................................... 4i ...................................................
SPECIFICATIONS - MMG205 MAGNUM MODEL MMG205 MMG205 Super Start Engine Make/Brand...................................................................... John Deere ...................................John Deere Model ............................................................................... PE6068HFG95..............................PE6068HFG95 EPA Tier ........................................................................... 4i ...................................................
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.
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.
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.
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.
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.
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 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.
• • • 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.
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.
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.
condition. SITE GENSET 7741 \ 7740 07:10 480V/277V 3-Phase Return Delay 10:00:00 Total 0.0 Hz 0.0 % 0.
• 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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 .
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).
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).
• • • • • • • • • 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.
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.
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.
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.
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.
VISCOUS FAN CLUTCH OPTION The viscous fan clutch option allows the engine cooling fan to engage at lower speeds and disengage at higher speeds, increasing cooling system efficiency. The cooling fan will engage at full speed when the coolant temperature rises. When the fan is operating at full speed, it will switch to a slower speed when the coolant temperature drops. There will be an audible difference when the engine cooling fan switches speeds.
AC WIRING DIAGRAM - 3 POSITION VOLTAGE SELECTOR SWITCH - 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.
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.
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.
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 TP
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 G
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
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 RECONNE
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 . .
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.
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.
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.
SERVICE LOG OIL GRADE AND TYPE: ____________________________ BRAND:___________________________________ COOLANT MIXTURE: ______________________________ BRAND:___________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ ______________________________________________
REV: B PART NO: 33722 05.01.