Magnum Manual Mmg320can6 Ops
Magnum Manual Mmg320can6 Ops
Magnum Manual Mmg320can6 Ops
DIESEL GENERATOR
MMG320CAN6
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 operators manual provides detailed operation and maintenance
procedures for the engine. Additional copies of the engine operators 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. Any wiring should be in compliance with the National Electrical Code (NEC), state and local codes
and Occupational Safety and Health Association (OSHA) guidelines.
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.
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............................................................................................................................ 10
UNIT DIMENSIONS ......................................................................................................................... 11
UNIT SERIAL NUMBER LOCATIONS ............................................................................................. 12
COMPONENT LOCATIONS ............................................................................................................ 13
MAIN CONTROL PANEL FEATURES ............................................................................................. 14
MAGNUM DIGITAL CONTROLLER (MDC) ..................................................................................... 16
DIGITAL CONTROLLER FEATURES AND FUNCTIONS ............................................................... 16
GENERATOR MONITORING .......................................................................................................... 17
ENGINE MONITORING ................................................................................................................... 18
WET STACKING ............................................................................................................................. 19
FINE VOLTAGE ADJUSTMENT ...................................................................................................... 19
PRESTART CHECK LIST ................................................................................................................ 20
ENGINE BREAK-IN REQUIREMENTS............................................................................................ 20
MANUAL STARTING OF THE GENERATOR ................................................................................. 21
AUTO (REMOTE) STARTING OF THE GENERATOR ................................................................. 22
SHUTTING DOWN THE GENERATOR........................................................................................... 23
MDC CONTROLLER INFORMATION DISPLAYS, FUNCTIONS, AND RESET ............................. 23
MAGNUM DIGITAL CONTROLLER (MDC) - GENERATOR OPERATIONAL STATUS ................. 23
MAGNUM DIGITAL CONTROLLER (MDC) - ALARM MANAGEMENT........................................... 24
MAGNUM DIGITAL CONTROLLER (MDC) - LIST OF ALARMS .................................................... 24
JOHN DEERE ECU INFORMATION DISPLAYS AND FUNCTIONS .............................................. 25
MAGNUM DIGITAL CONTROLLER (MDC) - HISTORY.................................................................. 26
ADJUSTING THE DISPLAY BACK LIGHTING ................................................................................ 27
RESETTING OF THE TIME TO SERVICE REMINDER ................................................................ 27
TROUBLESHOOTING AUTOMATIC SHUT DOWN CONDITIONS ................................................ 27
GENERATOR OUTPUT CONNECTION LUGS ............................................................................... 29
GENERATOR CAM LOCK CONNECTIONS OPTION..................................................................... 30
4 POSITION VOLTAGE SELECTOR SWITCH OPTION ................................................................. 31
CHANGING OUTPUT VOLTAGE ................................................................................................... 33
EMERGENCY STOP SWITCH ........................................................................................................ 34
MAIN CIRCUIT BREAKER............................................................................................................... 34
VOLTAGE REGULATION ................................................................................................................ 34
CONTROL PANEL RECEPTACLES................................................................................................ 35
DERATING FOR ALTITUDE ............................................................................................................ 35
REMOTE START TERMINAL BLOCK ............................................................................................. 35
TRANSFER SWITCH ....................................................................................................................... 36
AUTO EXERCISE TIMER ................................................................................................................ 37
DAILY WALK AROUND INSPECTION ............................................................................................ 37
ENGINE AND GENERATOR MAINTENANCE ................................................................................ 38
BASIC MAINTENANCE SCHEDULE - JOHN DEERE ENGINE ...................................................... 38
BELT TENSION................................................................................................................................ 39
LIFTING THE GENERATOR............................................................................................................ 39
TOWING THE TRAILER .................................................................................................................. 39
TRAILER WHEEL BEARINGS ......................................................................................................... 40
JACK MAINTENANCE ..................................................................................................................... 40
CHECKING GENERATOR DRIVE PLATE TORQUE ...................................................................... 41
AUXILIARY FUEL TANK OPTION ................................................................................................... 41
FUEL TRANSFER PUMP OPTION.................................................................................................. 41
VISCOUS FAN CLUTCH OPTION................................................................................................... 41
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 readers 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, could result in minor or moderate injury.
Indicates a hazardous situation which, if not avoided, could 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 you read and understand all of the instructions! This equipment was
designed for specific applications; DO NOT modify or use this equipment for any application other than
which it was designed for. Equipment operated improperly or by untrained personnel can be dangerous!
Read the operating instructions and familiarize yourself with the location and proper use of all instruments
and controls. Inexperienced operators should receive instruction from someone familiar with the equipment
before being allowed to operate or set up the generator. The following points should be practiced at all times:
The area immediately surrounding the generator should be dry, clean, and free of debris.
Make certain the generator is securely fastened to a good earthen ground before use. Installation
should be in compliance with National Electrical Code (NEC), as well as any state and local codes or
regulations.
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 120F (49C).
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 clean air filter with gasoline or other types of low flash point solvents.
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 start up.
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 any local, state or National
Electrical Code (NEC) guidelines.
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).
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. 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 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.
Engine running.
Burn/scald hazard;
pressurized steam.
SPECIFICATIONS
MAGNUM MODEL
MMG320CAN6
Engine
Make/Brand.............................................................................................................................John Deere
Model ......................................................................................................................................RG6090HF485
Horsepower - prime hp (kW) .................................................................................................384 (287)
Horsepower - standby hp (kW) ..............................................................................................422 (315)
Operating Speed rpm ............................................................................................................1800
Displacement in3 (L) ..............................................................................................................548 (9.0)
Cylinders - qty .........................................................................................................................6
Fuel Consumption - 100% prime gph (Lph) ..........................................................................17.9 (67.8)
Battery Type............................................................................................................................Group 31
Battery Voltage (Quantity per Unit) .........................................................................................12V (2)
Battery Rating .........................................................................................................................1000 CCA
Generator
Make/Brand.............................................................................................................................Marathon Electric
Model ......................................................................................................................................432PSL6506
Type, Insulation.......................................................................................................................Brushless, H
Generator Set (Engine/Generator)
600V (3)
480V (3)
208V (3)
240V (1)
3 - Standby kW (kVA) ........................281 (351) ........... 275 (344)........... 238 (298) ...........N/A
Amps - 3 Standby A ...........................338 .................... 413 .................... 826.....................N/A
3 - Prime kW (kVA) ...........................258 (322) ........... 254 (318)........... 221 (276) ...........N/A
Amps - 3 Prime A ...............................310 .................... 382 .................... 767.....................N/A
1 - Standby kW (kVA).........................0 (0) ................... 0 (0)................... 0 (0) ...................N/A
Amps - 1 Standby - 240V A................0 ........................ 0 ........................ 0.........................N/A
1 - Prime kW (kVA) ............................0 (0) ................... 0 (0)................... 0 (0) ...................N/A
Amps - 1 Prime - 240V A ...................0 ........................ 0 ........................ 0.........................N/A
Frequency Hz .........................................................................................................................60
Power Factor...........................................................................................................................0.8 (3)
Weights
Dry Weight, Skid Mounted lbs (kg) ........................................................................................8039 (3646)
Operating Weight, Skid Mounted lbs (kg) .............................................................................11499 (5215)
Dry Weight, Trailer Mounted lbs (kg) ....................................................................................10912 (4949)
Operating Weight, Trailer Mounted lbs (kg) ..........................................................................14372 (6519)
Capacities
Fuel Tank Volume gal (L) .......................................................................................................459 (1738)
Usable Fuel Volume gal (L) ...................................................................................................423 (1601)
Coolant (incl. engine) qt (L) ...................................................................................................75.0 (70.9)
Maximum Run Time hrs ........................................................................................................24
AC Distribution
Circuit Breaker Size ................................................................................................................1200
Voltage Selection ....................................................................................................................Link/Reconnect Board
Voltage Regulation ..................................................................................................................+/- 1%
Voltages Available 1 .............................................................................................................N/A
Voltages Available 3 .............................................................................................................208, 480, 600
Trailer
Number of Axles .....................................................................................................................2
Capacity - Axle Rating lbs (kg) ..............................................................................................8000 (3629)
Tire Size in .............................................................................................................................17.5
Brakes.....................................................................................................................................Electric
Hitch - Standard ......................................................................................................................3" Ring
Maximum Tire Pressure psi ...................................................................................................125
10
UNIT DIMENSIONS
MAGNUM MODEL
MMG320CAN6
ER GENC
STOP
Dimensions (L x W x H)
Skid Mounted in (m) ......................................................................................................................156 x 60 x 90
(3.96 x 1.52 x 2.29)
Trailer Mounted in (m) ...................................................................................................................230 x 102 x 110
(5.84 x 2.59 x 2.79)
11
UNIT ID Tag
VIN Tag
Manufactured by
MAGNUM POWER PRODUCTS LLC
TIRE / PNEU
RIM / JANTE
DATE:
00/0000
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.
V.I.N./N.I.V.:
00000000000000000
XXX000
TYPE: TRAILER
MODEL:
SEE OWNERS
MANUAL FOR
ADDITIONAL
INFORMATION
VOIR LE
MANUEL DE
LUSAGER
POUR
PLUS DE
RENSEIGNEMENTS
Serial Number
Model
Mfg. Code
Skidded WT (lbs/kg)
1 ph. 1.0PF
rpm/freq
3 ph. .8PF
3 ph. 1.0PF
KW
KVA
V
A
insul. class
RATING
FOR ELECTRICAL
EQUIPMENT ONLY.
POUR MATERIAL
ELECTRIQUE SEULEMENT.
12
COMPONENT LOCATIONS
Engine Access
Central
Lift Point
Ladder
Generator
Access
ER GENC
Y
Emergency
Stop
STOP
Radiator
Drain Port
Oil
Drain Port
Engine
Battery
Reconnect
Board
Access
Control
Panel
Access
Radiator
Access Panel
Engine
Exhaust
Ladder
Engine Service
Access
Fuel
Fill
13
16
6
MAN AUT
Ready
PF
RPM
0
15
kW
0.00
0
0
14
13
14
12
11
10
1. MAIN CIRCUIT BREAKER FOR CONNECTION LUGS: This breaker will disconnect power to the connection
lugs (items 1-2). 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.
2. OPTIONAL CIRCUIT BREAKERS FOR CAM LOCK CONNECTORS: The MMG320CAN6 has two optional
400A breakers. The left breaker protects SET 1 cam locks. The right breaker protects SET 2 cam locks.
3. OPTIONAL CONTROL PANEL LIGHT
4. MAGNUM DIGITAL CONTROLLER (MDC): Refer to page 16 for additional information.
5. AIR FILTER METER: This gauge shows the condition of the air filter when the engine is running.
6. 50A CIRCUIT BREAKERS (3): Circuit breakers for the 120/240V twist-lock receptacles.
7. 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.
8. REMOTE START TERMINAL BLOCK: Used to connect the generator to a dry-contact closure switch for remote
starting of the generator.
9. 120V GFCI DUPLEX RECEPTACLES (2): Receptacles for additional equipment that may require Ground Fault
Circuit Interrupt (GFCI) protection.
10. OPTIONAL CAM LOCK CONNECTORS: Series 16 Taper Nose 400A, 600V cam locks are connected here.
Refer to page 30 for more information.
11. ENGINE ACCESSORY CONNECTION: Connection for battery charger and other engine accessories.
12. OUTPUT GROUND CONNECTION: Ground lug for attaching the generator to a good earthen ground. (The
generator neutral is bonded to ground when shipped from the factory.)
13. CONNECTION TERMINAL LUGS: External loads are wired to these lugs.
14. 20A CIRCUIT BREAKERS (2): Circuit breakers for the 120V GFCI receptacles.
15. OPTIONAL AUXILIARY LIGHT SWITCHES: These switches operate the control panel and interior lights.
16. BREAKER HANDLE EXTENSION: This provides additional leverage to the main breaker switch.
15
16
MANUAL button: Press this button to change from the automatic (remote) starting mode to manual
starting mode.
AUTO button: Press this button to change from manual starting mode to automatic (remote) starting
mode.
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.
GENERATOR MONITORING
Generator information is shown on the Liquid Crystal Display (LCD) window in a toggling manner with the engine
information after the first 60 seconds of operation, then every five seconds thereafter. The Generator Display screen
will show frequency, nominal voltage, nominal amperage, line to neutral voltage, line to line voltage and amperage.
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 10% or less, will not cause any particular problems. Every effort
should be made to distribute the load equally between all lines.
17
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 five seconds thereafter. The Engine Display screen
will show oil pressure, engine coolant temperature, fuel level and battery voltage.
Oil Pressure: Displays engine oil pressure. The display registers oil pressure between 0-100 psi (10-689
kPa). Normal operating pressure is between 35-80 psi (241-552 kPa).
Engine Temp: Displays the temperature of the engines coolant. If the coolant temperature exceeds the
maximum water temperature of 230F (110C) the engine will automatically shut down. Zero will be displayed
until a minimum temperature of 100F (38C) is reached.
Fuel Level: Displays the level of fuel in the tank by percentage (50% = 1/2 tank, 75% = 3/4 tank, etc.). If the
fuel level drops below a programmed low fuel point, usually at 15%, a low fuel warning and optional audio
alarm will be activated. If the fuel level drops below the programmed low fuel limit, usually at five percent,
the engine will automatically shut down.
Battery Volts: Displays the engine battery voltage. A normal reading is 13-14V on 12 volt systems and 2426V on 24 volt systems (with the engine running).
Additional information may be viewed while the unit is in Manual or Auto mode. By pressing the PAGE SELECT
button, the operator will select one of the following screens; Running screen, Password screen, or History screen.
In each of these page selections the operator may press the or buttons on the DIAGNOSTICS keypad to
display additional information as follows:
18
Running screen: The operator may press the or buttons on the DIAGNOSTICS keypad to
display the Alarm List screen, ECU Alarm List screen, Run Hours screen, ECU Values screen, Engine
Display screen and Generator Display screen.
Password screen: The operator may press the or buttons on the DIAGNOSTICS keypad to
move the cursor (>) up or down a list of text.
History screen: The operator may press the or buttons on the DIAGNOSTICS keypad to move
the cursor (>) up or down a list of recent alarm or shutdown codes. Pressing the ENTER button at a particular
selection will allow the operator to scroll to the right in the LCD window to view the generator operating
parameters at the time of the alarm or shutdown. The history of alarms or codes is 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 117 codes. When full, the controller will automatically
remove the oldest file. These codes will not be lost when the CONTROL ON/OFF toggle switch is powered
off.
Note: To view the display screens longer, push the PAGE SELECT button on the DIAGNOSTICS keypad until
you reach the Ready screen. Then press the or buttons to navigate to the screens you want. The screens
will display for approximately 45 seconds.
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.
Voltage
Adjustment
Screw
CONTROL
ON
CONTROL
OFF
V Detect is a 45 second time delay and countdown process before the MDC
records the generator nominal output voltage. This nominal generator voltage
is then compared to the current set point voltage of the link board or voltage
selector switch. If the nominal voltage recorded by the controller is greater than
or lower than the current set point voltage of the link board or voltage selector
switch setting by 10% or more, the controller will shut the generator down automatically. The display will read: Wrn
Gen L1 <V, Wrn Gen L2 <V, Wrn Gen L3 <V or Sd Gen L1 <V, Sd Gen L2 <V, Sd Gen L3 <V. This means
the controller warned (Wrn) or shut down (Sd) the unit due to an output voltage irregularity.
The output voltage of the generator may be adjusted after the generator is running by using the fine voltage adjustment
19
screw. The adjusting screw is located directly below the CONTROL ON/OFF toggle switch on the control panel.
This screw turns a rheostat that will provide an increase (+) or a decrease (-) in the generator output voltage as
displayed on the Generator Display screen on the MDC. If the voltage is increased or decreased too fast or too slow,
the unit will automatically shut down. This adjustment needs to be made within the 45 second delay and count down
to zero period.
To adjust the output voltage, check the output voltage on the Generator Display screen. Look at the L1N voltage
or the L12 voltage on the display. The generator nominal output voltage should be within 10% of the voltage rating
on the link board or voltage selector switch. Use a flat head screwdriver to turn the screw in the desired direction
until the required voltage shown on the LCD window matches the stated voltage on the link board or voltage selector
switch.
For Example: With the voltage selector switch set to 208/120V 3-phase position, the voltage shown on the Generator
Display screen must be within 10% of the 208/120V position (188-228 V line to line/108-132 V line to neutral).
Note: Each time the link board or voltage selector switch is changed from one setting to another, an adjustment will
need to be made to the fine voltage using this adjustment screw.
Read and understand ALL safety sections at the beginning of this manual.
Make sure the CONTROL ON/OFF toggle switch is in the OFF/O position.
Make sure the circuit breakers are switched OFF/O.
Check that the generator is properly grounded to a good earthen ground. Installation should be in
compliance with National Electrical Code (NEC), as well as any state and local codes or regulations.
Check all electrical connections at the connection lugs and cam lock receptacles (if equipped). Are
they wired correctly? Are they tight?
Check the link board or voltage selector switch and make sure that it is set to the desired voltage.
Is the voltage selector switch (if equipped) locked?
Is the generator sitting level?
Thoroughly check for any water inside the unit, on or near the generator. Dry the unit before starting.
Check oil, coolant and fuel levels and engine battery connections.
Check engine fan belt tension and condition.
Check engine fan belt guard.
Check engine exhaust system for loose or rusted components.
Check radiator and surrounding shroud for debris.
Are any of the generator covers loose or missing?
Are all preventive maintenance procedures up to date?
Check that the battery disconnect switch is on, if equipped.
20
DANGER
CARBON MONOXIDE: USING A GENERATOR INDOORS CAN KILL YOU IN MINUTES.
2. The Liquid Crystal Display (LCD) window will quickly display system information, all Light Emitting Diodes (LEDs)
will flash.
3. The LCD window will indicate MAN (Manual) mode and Ready. The READY/MANUAL LED will be lit.
Note: The unit must be in the MAN mode with the READY/MANUAL LED lit to start the unit.
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.
21
7. The LCD window will then toggle from the Running screen to the Generator Display screen and then to the
Engine Display screen.
p y
g
p y
8. 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 PAUSE. The engine will make two more attempts to start for a total
of three crank cycles.
9. Should the engine not start and run within three starting cycles, the LCD window will show SD Start fail. The
starting sequence may be repeated after the starter has had a minimum of two minutes to cool. Press the FAULT
RESET button to clear the controller. To start the unit, press the green ENGINE START button.
Note: The engine controller may skip the preheat engine steps on some of the larger models.
10. 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 LCD window will show engine and generator operating parameters. Temperature will be shown as
0 until the engine temperature is approximately 100F (38C).
11. Check the generator for excessive noise or vibration and any coolant, oil, or fuel leaks before applying any loads.
12. Check that the AC output voltage is correct. The output voltage can be fine adjusted by using the fine voltage
adjustment screw (rheostat), as described on page 19.
13. Check that the frequency (Hz) is correct. With no loads connected to the generator, the frequency should read
approximately 60 Hz, depending on the type of engine governing used.
14. 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.
22
2. If a check of the remote start circuit is desired, remove the wires from the remote start terminal block.
Press the AUTO button, the Liquid Crystal Display (LCD) window should highlight AUT in the upper
left corner. Attach a jumper wire (minimum 16 gauge) across the two terminals on the remote start
terminal block. This applies a ground to the Digital 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 unit is in Auto mode. The LCD window should have AUT highlighted in the upper left corner.
5. Close the main circuit breaker (set to ON/I).
6. Secure the generator by closing and locking all access doors.
7. The generator is now ready for remote starting.
Engine State
AfterCool
Cooling
Cranking
EmergMan
Init
Loaded
Not Ready
Pause
Prestart
10
Ready
Description
Engine aftercooling, cooling pump output is closed.
The unit is cooling before stop.
Engine is cranking.
Emergency manual gen-set operation.
Autotest during controller power on.
The unit is running at nominal speed and GCB OPEN/
CLOSE is closed.
The unit is not ready to start.
Pause between start attempts.
Prestart sequence in process, prestart output is closed.
The unit is ready to run.
23
No.
Engine State
Description
11
Running
12
Shutdown
13
Starting
14
Stop
No.
Electrical State
Description
StabilTO
Stabilization Timeout
Type
Description
Warning (WRN)
Shutdown (SD)
When the shutdown alarm comes up, the digital controller opens
outputs GCB CLOSE/OPEN, FUEL, SOLENOID, STARTER and
PRESTART to stop the engine immediately.
No.
Events
Specification
Information on
Protection
Binary Output
Type
Available
AnInIOM Sd
SD
YES
AnInIOM Wrn
WRN
YES
SD
YES
Binary Input
CONFIG.
YES
ChrgAlternFail
WRN
YES
EmergencyStop
SD
NO
Engine Temp Sd
SD
NO
WRN
YES
Fgen<, >
SD
YES
10 Fuel Level Sd
SD
YES
WRN
YES
11
24
Description
Shutdown alarm configurable on the input of IG-IOM/
IGS-PTM.
Warning alarm configurable on the input of IG-IOM/
IGS-PTM.
If the controller switches off during starting sequence
due to bad battery condition, it doesnt try to start again
and activates this protection.
Configurable Warning/Shutdown alarms on the inputs
of IL-NT.
Failure of the alternator to charge the battery.
If the red Emergency Stop switch is pushed or opened,
shutdown is immediately activated.
Water temperature is greater than Sd Water Temp setpoint.
Water temperature is greater than Wrn Water Temp
setpoint.
The generator frequency is out of limits given by Gen >f
and Gen <f setpoints.
Fuel level is smaller than Sd Fuel Level setpoint (5%).
Fuel level is smaller than Wrn Fuel Level setpoint
(15%).
No.
12
13
14
15
16
Events
Specification
GCB fail
Igen unbl
Low BackupBatt
Oil Press Sd
Oil Press Wrn
Information on
Protection
Binary Output
Type
Available
SD
SD
WRN
SD
WRN
NO
NO
NO
NO
YES
17 Overload
SD
YES
18 Overspeed
SD
YES
19 ParamFail
NONE
NO
20 PickupFault
SD
NO
21 Sd IOM fail
SD
NO
22 SprinkIActive
23 Start failed
24 Stop fail
WRN
SD
SD
NO
YES
YES
25 Ubat
WRN
YES
26 Underspeed
SD
YES
27 Vgen<, >
SD
YES
28 Vgen unbal
SD
NO
WRN
NO
WRN
NO
31 WrnMaintenance
WRN
NO
Description
Failure of the generator circuit breaker.
The generator current is unbalanced.
RTC backup battery is flat (low).
Oil pressure is smaller than Sd Oil Press setpoint.
Oil pressure is smaller than Wrn Oil Press setpoint.
The load is greater than the value given by Overload
setpoint.
The protection comes active if the speed is greater than
Overspeed setpoint.
Wrong checksum of parameters. Happens typically
after downloading new firmware or changing of the
parameter. The controller stays in INIT mode. Check all
parameters, write at least one new parameter.
Failure of the magnetic pick up sensor for speed measurement.
Shutdown alarm in case of lost connection to IOM/IGSPTM module.
The protection is active if the output Sprinkler is closed.
Unit did not start.
Unit did not stop.
Battery voltage is out of limits given by Batt Undervolt
setpoints.
During starting of the engine, when the RPM reaches
the value of Starting RPM setpoint, the starter is
switched off and the speed of the engine can drop
under Start RPM again. Then the Underspeed protection becomes active. Protection evaluation starts 5 seconds after startup.
The generator voltage is out of limits given by Gen <V
and Gen <V setpoints.
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 WrnMaintenance
setpoint. The protection comes active if the running
hours of the engine reach this value.
25
the unit. To resume operation, the fault condition must be resolved and the code cleared from the display.
Figure 1
Diagnostic messages are read and displayed in the ECU Alarm List. The Suspect Parameter Number (SPN)*,
Failure Mode Identifier (FMI) and Occurrence Counter (OC) are shown together with a description (if possible). One
SPN*/FMI describes one failure. If FMI is equal to zero or one, WRN is displayed in the ECU Alarm List. For any
other FMI value, Fls is displayed. Detailed SPN*/FMI information may be found in the SAE HS-1939 Publication,
or refer to the engine manufacturers ECU error codes list. The following table displays the ECU messages and their
descriptions.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
SPN
Description
SPN:100
EngOil Press
SPN:102
Boost Press
SPN:105
Intake Temp
SPN:110
EngCool Temp
SPN:175
EngOil Temp
SPN:629
Controller #1
SPN:636
PositionSensor
SPN:637
TimingSensor
SPN:651
InjectorCyl#1
SPN:652
InjectorCyl#2
SPN:653
InjectorCyl#3
SPN:654
InjectorCyl#4
SPN:655
InjectorCyl#5
SPN:656
InjectorCyl#6
SPN:677
EngStartRelay
SPN:1485
ECU MainRelay
SPN:3719.15
High soot load caution
SPN:3719.16
Very high soot load warning
SPN:3719.00 Very high soot load - needs service
*Note: The Suspect Parameter Number (SPN) is displayed as FC on the bottom left of the LCD window. Refer to
Figure 1.
Record Structure
Abbreviation
AIM1
Date
OilP
26
Historical Value
No.
Record Structure
Abbreviation
FC
Vg2
Generator voltage L2
RPM
Engine speed
Ig2
Ubat
Battery voltage
FMI
10
EngT
Historical Value
Generator current L2
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 SHUT DOWN
1. Check the fuel level on the Liquid Crystal Display (LCD) window. Confirm that the generator is sitting
level to ensure an accurate reading.
27
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
bolts from the control panel to access the inside of the control box. Consult the appropriate 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 SHUT DOWN
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 operators manual provided with the unit.
LOW COOLANT LEVEL SHUT DOWN
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). Consult
the engine operators manual for additional information.
HIGH COOLANT TEMPERATURE SHUT DOWN
1. Check the coolant level in the overflow jug.
2. Restart the engine and read the coolant temperature to verify High Coolant Temperature Shut down.
Stop the engine immediately if the coolant temperature is 230F (110C) 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. Consult the engine
operators manual for additional information on engine overheating.
OVERCRANK SHUT DOWN
1.
2.
3.
4.
28
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) as well as any local or state guidelines as
required by law. 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 engine start 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 BUILDINGS ELECTRICAL SYSTEM
CAN CAUSE POTENTIALLY LETHAL VOLTAGES TO BACKFEED ONTO 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 slot in the bottom of the box.
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.
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 HAVE this ground lug 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 NATIONAL ELECTRICAL CODE (NEC), AS WELL AS
ANY STATE AND LOCAL CODES OR REGULATIONS.
29
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) as well as any local or state guidelines as
required by law. 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 engine start switch are in the OFF/O position and that the negative
(-) battery cable is disconnected. Potentially lethal voltages may be present at the
generator cam lock receptacles.
DANGER
IMPROPER OR INCORRECT CONNECTIONS TO A BUILDINGS ELECTRICAL SYSTEM
CAN CAUSE POTENTIALLY LETHAL VOLTAGES TO BACKFEED ONTO 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 running power cables equipped with series 16 taper nose 400A, 600V cam lock
plugs up through the slot in the bottom of the box and into the cam lock receptacles. Secure the connection by rotating
the plug a half turn to the right. 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.
WARNING
Never attempt to disable or modify the lug door safety switches. Equipment damage,
personal injury or death may result.
SET 1
SET 2
L1
L2
L3
N (Neutral)
G (Ground)
30
Black
Red
Blue
White
Green
A ground connection is located on the far right of each cam lock set. Each set 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 NATIONAL ELECTRICAL CODE (NEC), AS WELL AS ANY STATE AND
LOCAL CODES OR REGULATIONS.
WARNING
On units equipped with two sets of cam locks, make sure all connections to the cam
lock receptacles are made to one side only. i.e. DO NOT attach L1, L2 and L3 to the
left side and Neutral and Ground to the right side. Refer to page 14 for breaker
locations.
NEVER CHANGE THE VOLTAGE SELECTOR SWITCH WHILE THE ENGINE IS RUNNING. This will cause severe arcing and damage to the switch and generator windings.
The four position selector switch must be at 480/277V when the two position selector switch
is at or switching to 600V.
Unit
Configuration
Switch Configuration
600V
Voltage Configuration
480V
L1
L1 - L2 = 600V L1 - N = 348V
L2 - L3 = 600V L2 - N = 348V
L3 - L1 = 600V L3 - N = 348V
N=
T1
T4
T7
348/600V
3-Phase
L-L
OR
T10
N T11
T12
T9
T8
T5
T6
T2
T3
L3
600V
L2
L-N
480V
L1
L1 - L2 = 480V L1 - N = 277V
L2 - L3 = 480V L2 - N = 277V
L3 - L1 = 480V L3 - N = 277V
N=
T1
T4
T7
277/480V
3-Phase
L-L
OR
T10
T12
T9
N T11
T8
T5
T6
T2
T3
L3
L-N
L2
31
Unit
Configuration
Switch Configuration
600V
Voltage Configuration
480V
L1 - L2 = 208V L1 - N = 120V
L2 - L3 = 208V L2 - N = 120V
L3 - L1 = 208V L3 - N = 120V
N=
L1
120/208V
3-Phase
T7
T1
T10
T4
L-L
OR
N
T12
T9
L3
T6
T5
T2
T11
T3
T8
L2
L-N
600V
120/240V
3-Phase
480V
L1 - L2 = 240V L1 - N = 120V
L2 - L3 = 240V L2 - N = 208V
L3 - L1 = 240V L3 - N = 120V
N=
OR
600V
480V
T6
120/240V
1-Phase
T3
OR
T8
T12 T2
T11
T10
T7
T4
T1
N
L3
L1
T5
T9
120V
120V
240V
The voltage selector switch is equipped with a locking mechanism. Once the proper voltage has been selected, push
the red latch on the inside of the switch handle up and insert a padlock through the handle. By locking the handle in
place you will prevent unauthorized personnel from changing the switch settings.
The two 120V GFCI receptacles should not be used in the 480/277 and 600/348 voltage settings and the three 240V
twist-lock receptacles should not be used in the 600/348 voltage setting as the voltage will be higher and equipment
damage could result.
32
DANGER
NEVER ATTEMPT TO CHANGE THE VOLTAGE WHILE THE ENGINE IS RUNNING.
LETHAL VOLTAGE MAY BE PRESENT AT THE CONNECTION LUGS ON THE SHORTING (LINK) BOARD.
To receive 480/277 3 voltage at the connection lugs, the shorting (link) board must be attached in the lower position
as shown in the illustration. For 208/120 3 voltage, the shorting (link) board must be in the upper position as shown
in the illustration. If the board needs to be changed from one setting to the other, remove all of the 1/2 nuts that hold
the shorting (link) board down and move it to the new position. Replace all of the hardware and tighten it to 25 ft-lbs.
of torque.
Reinstall the reconnect box door and start the generator by following the Prestart Check List on page 20.
Remove all
1/2 nuts
L1
T1
T4
T7
L-L
T10
T12
L3
T11
T9
T8
T6
T5
T3
L-N
L2
T2
L1
T7
T1
T10
T4
L-L
N
T12
T5
T2
T9
T6
L3
T3
T11
T8
L-N
L2
Link Board Attached in
208Volt 3 Position
33
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.
The generator is equipped with one emergency stop switch, located on the rear of the
unit next to the control door. The red switch is clearly labeled EMERGENCY STOP.
The switch can be accessed and activated with all doors closed and locked.
STOP
ON/I
ON/I
Make sure that any problems that cause the main circuit breaker to trip are corrected
before returning the switch to the ON/I position.
OFF/O
OFF/O
WARNING
The main circuit breaker interrupts power to the customer connection lugs only. The
control panel receptacles have power even if the main circuit breaker is in the OFF/
O position. To disconnect power to the receptacles, use the individual circuit
breakers located near each receptacle.
VOLTAGE REGULATION
The electronic voltage regulator controls the output of the generator by regulating the current into the exciter field.
The regulator has three screwdriver adjustable potentiometers that may be adjusted for voltage, stability and voltage
roll-off (U/F). The voltage regulator on your unit is adjusted before shipment from the factory. Contact Magnum Power
Products LLC for additional information before attempting to adjust the voltage regulator.
Note: For units equipped with a Marathon DVR2000E+ digital voltage regulator, please refer to the Marathon operating
manual provided with the unit.
34
Power to the receptacles is available any time the generator is running, EVEN IF THE MAIN
CIRCUIT BREAKER IS OFF/O, 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.
Note: When the shorting board is in position for 480/277V 3, voltage at the two GFCI duplex receptacles is 139V
and the voltage at the three twist-lock receptacles is 240/139V. Magnum Power Products LLC does not recommend
using the receptacles in the 480V position. When the shorting board is in position for 208/120V 3, voltage at the
three twist-lock receptacles and the two GFCI receptacles is 208/120V.
Remote
Start
Switch
Terminals
35
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 source.
Installation should be in compliance with National Electrical Code (NEC), as well as any
state and local codes or regulations.
When the generator is used as a standby power supply, it must be equipped with a transfer switch which isolates it
from the utilitys 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.
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 BACK UP TO SOME OTHER TYPE OF POWER SUPPLY.
Incoming
Utility
Power
Utility
Meter
Emergency
Distribution Panel
(Generator Power)
Main Distribution
Panel
(Utility Power)
Transfer
Switch
Power From
Generator
WHITE = Incoming
Utility Power
GRAY = Normal Utility
Power Circuit
BLACK = Emergency
Generator Power Circuit
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 local and state regulations. Familiarize yourself with all instructions and warning labels supplied with the switch.
36
WARNING
ONLY a licensed electrician should perform any wiring and any related connections
to the generator. Installation should be in compliance of the National Electrical Code
(NEC) as well as any state or local codes or 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 engine start
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.
Press the PAGE SELECT button until Password appears at the top of the screen.
Press the down arrow until Date/Time is selected and press ENTER.
Press the down arrow until Timer1 Repeat is selected and press ENTER.
Choose the day or days the unit should run and press ENTER.
Press the down arrow until Timer1 ON Time is selected and press ENTER.
Adjust the desired time to start running and press ENTER.
Press the down arrow until Timer1Duration is selected and press ENTER.
Adjust the time period to the length of time the unit should run after starting, and press ENTER.
Press PAGE SELECT three times to return to the main menu.
Press the AUTO button to switch modes to automatic.
Note: The controller must be in Auto mode to run at the programmed time. Use a trickle battery charger or solargizer
to prevent the controller from draining the battery while in Auto mode.
CAUTION
Failure to perform a daily inspection may result in serious damage to the prime mover.
37
Make sure the engine start switch is turned to the OFF/O position.
Verify that all circuit breakers are open (OFF/O).
Activate (push in) the EMERGENCY STOP button.
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.
If the unit is connected to a remote start or transfer switch, make sure the remote switch is also off and tagged.
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.
Item
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
38
Daily
250
Hrs.
500
Hrs./12
Months
2000
Hrs./ 24
Months
As
Required
Item
Daily
*
**
250
Hrs.
500
Hrs./12
Months
2000
Hrs./ 24
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.
BELT TENSION
John Deere engines use two types of belt tensioners: manual and automatic. Adjust the belt using the manual
tensioner according to the manufacturers specifications. The automatic tensioner cannot be adjusted or repaired
and is designed to maintain proper tension over the belts life. Units with the automatic belt tensioner must be inspected
according to the manufacturers specifications.
A large central lift point is located on the top of the generator. The central lift point
is connected to a lift structure inside the unit. Attach a sling or hook directly to
the cental lift point only if the devices are in good condition and the equipment
being used to raise the unit has sufficient capacity. Approximate weights can be
found on page 10. Always remain aware of others around you when moving or
lifting the generator. Keep the cabinet doors closed and locked.
39
4. Check for proper inflation of the trailer tires. Maximum tire pressures can be found 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).
4
5
Note: After the first road use, re-torque the lug nuts in sequence.
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 light
weight oil.
TOP-WIND MODELS
OIL
GREASE
GREASE
OIL
40
OIL
OIL
OIL
ft-lbs (Nm)
33 (45)
FUEL TRANSFER
INLET
Note: If the external bulk fuel supply is already connected, the unit does not have to be
shut down to turn the fuel transfer pump option on or off.
2. Attach the external bulk fuel supply to FUEL TRANSFER INLET fitting on the unit.
3. Turn on the fuel transfer switch.
41
H3
600 VOLT
SELECTOR SWITCH
6
4
50HZ
60HZ
3
F+
F7
BK
BN
BN/WT
RD
BK
WT
SE350
VOLTAGE REGULATOR
4 AMP FUSE
ON REGULATOR
X1
BK
H2
H4
BK
X2 X3
600v
PRIMARY
MTB PIN1
(FUEL)
(2.5K, 2 WATT)
VOLTAGE
ADJUSTMENT
P RD/OR
N RD/VI
RD/VI
YL
RD/OR P
21 PIN
CONN2
BK
BK/WT
BK
BK
OR
X1
H2
WT
240v
SECONDARY
H1
BN
RD
X4
H1
X3
BK
BUCK XFORMER
X2
NO
X4
NC
VOLTAGE RELAY
TO CONN1 PIN B
SEE DC DRAWING
480/600V SHORT
208V SHORT
CIRCUIT
BREAKER
12VDC
SHUNT
T4
T7
L1
T5
T8
L2
RECONNECT
BOARD
T6
T9
L3
CT-3
L3
CT-2
L2
L0
GND
(L0)
(T9)
(T7)
RD
BK
GROUND
TO GEN FRAME
3/0
MECHANICAL LUGS
CT-1
L1
3/0
QTY 3 BLK 3/0
WT
P
N
21 PIN
DEUTSCH PLUG
BK
BK
BK
BK
BK
BK
RD
BK
BN
BN
GN/YL 10GA
GN/YL 10GA
GN/YL 10GA
GN/YL 14GA
GN/YL 14GA
T4
T5
T6
T7
T8
T9
T1
T2
T3
50A
CIRCUIT
BREAKER
F+ F-
GENERATOR
20 AMP
G.F.I.
RECEPTACLE
BK
POWER
RELAY
WT
GROUND
TO
FRAME
50A
CIRCUIT
BREAKER
W
BL
BL
20 AMP
90479_ORG_10.08.13
50A
CIRCUIT
BREAKER
20 AMP
G.F.I.
RECEPTACLE
20 AMP
BK
BN1
3/0
QTY 3 BLK 3/0
QTY 2 BLK 6
BK
COM
BL
BN/WT1
RD/OR
BN/WT3
BN2
BN/WT2
BN
BN/WT1
BN1
3/0
QTY 3 BLK 3/0
QTY 2 BLK 6
BK
T10
T11
T12
BK
42
BK
BK
AC WIRING DIAGRAM
BL
BL
33
TO L0
H1
X2
X3
X1
USED ON
SOME
NON-POWER
ZONE
MODELS
BN
BLK
H2
H4
L3
TO LUG
BLOCK
L0 GND
GROUND
OR
21 PIN
DEUTSCH
CONN-2
OR
OR
BLK
15
31 PIN
DEUTSCH
CONN-2
31 PIN
DEUTSCH
CONN-2
USED ON
MMG235
AND
HIGHER
21 PIN
DEUTSCH
CONN-1
TO L0
BLK
VOLTAGE RELAY
WHT
TO T9
TO T7
BR/WT
BN
YEL
BLK
RED
T9
T7
RECONNECT
DOOR
USED ON
SOME
NON-POWER
ZONE
MODELS
34
33
E1
E2
E3
40
3
4
F+
F-
39
HEATER
GEN
RD
BK
WT
BK
RD
WT
BN/WT
BN
OR
OR
31 PIN
DEUTSCH
CONN-2
31 PIN
DEUTSCH
CONN-2
SPLICE
SPLICE
BR/WT
BN
WIRE
TO
EDISON
PLUG
F+
F-
DVR
REMOTE
VOLTAGE
DOWN ADJUSTMENT
UP
21 PIN
DEUTSCH
CONN-1
BR/WT
BN
GENERATOR
HEATER
21 PIN
DEUTSCH
CONN-1
USED ON
MMG235
AND
HIGHER
GEN
NEUTRAL
BAR
T4
T3
T2
T1
OR
31 PIN
DEUTSCH
CONN-2
DEDICATED
240V GEN
OR
L3
L2
T9
L0
L1
T7
USED ON
MMG185
AND
LOWER
HEATER
DROOP
OFF
UP
CGND
DOWN
L2
21 PIN
DEUTSCH
CONN-2
USED ON
MMG235
AND
HIGHER
USED ON
MMG185
AND
LOWER
OR
21 PIN
DEUTSCH
CONN-1
L1
BR/WT
BN
BR
OR
BR/WT
BN
21 PIN
DEUTSCH
CONN-2
POWER ZONE
CONTROL ONLY
DVR 2000E+
BR/WT
RECONNECT
DOOR
USED ON
SOME
NON-POWER
ZONE
MODELS
34
33
PMG
CIRCUIT
BREAKER
TO GEN VOLT L3
TO GEN VOLT L1
LUG
DOOR
NON-POWER
ZONE
GN/YL
TO T7
TO 120V BREAKERS
BUCK TRANSFORMER
L2
L3
NOTE: REPEAT ALT CAM LOCK FOR ADDITIONAL SETS.
USED ON
MMG185
AND
LOWER
21 PIN
DEUTSCH
CONN-2
TO T8
BR/WT
H3
BUCK XFORMER
RECONNECT
DOOR
34
RED
NC
NO
COM
L2
ALT
CAM L1
LOCK
PANEL
GROUND
BRN
BRN
L0 GND
TO LUG
BLOCK
BLK
L1
L3
X4
PMG
WHT
POWER
RELAY
CIRCUIT
BREAKER
L2
WHT
BR/WT
BR/WT
P2
T7
T9
OR
(2.5K, 2 WATT)
VOLTAGE
ADJUSTMENT
SEE POWER
ZONE OPTION
21 PIN
DEUTSCH
CONN-1
BR/WT
POWER
ZONE
CONTROL
ONLY
E1
E1
P1
F+
F+
F-
F-
T7
T9
OR
(2.5K, 2 WATT)
VOLTAGE
ADJUSTMENT
SEE POWER
ZONE OPTION
VR1
VR2
E3
PM300 VOLTAGE
REGULATOR
E2
E3/4
A1
NOT CONNECTED TO
T7 & T9 FOR V-FLEX
PM500 VOLTAGE
REGULATOR (ALTERNATE)
46
A1
VOLT REGULATION
RELAY
TO CONTACT ON
4 POS PHASE SWITCH
NOT CONNECTED TO
T7 & T9 FOR V-FLEX
A2
PM500 VOLTAGE
REGULATOR (ALTERNATE)
POWER
37
ZONE
38 CONTROL
90415_M_09.25.13
E3
TO GND BAR
NOT CONNECTED TO
T9 FOR V-FLEX OR PM500
GEN
T7
F-
F+
T9
PMG
W/4 POS
PHASE SWITCH
A2
POWER
37
ZONE
38 CONTROL
V-FLEX ONLY
PMG
NOT CONNECTED TO
T9 FOR V-FLEX OR PM500
GEN
T7
F-
PM300 VOLTAGE
REGULATOR
T9
F+
V-FLEX ONLY
31 PIN
DEUTSCH
CONN-2
E2
VR2
VR1
F-
F+
P1
E1
21 PIN
DEUTSCH
CONN-1
E3/4
F-
F+
31 PIN
DEUTSCH
CONN-2
E1
LUG
DOOR
NON-POWER
ZONE
P2
POWER
ZONE
CONTROL
ONLY
LUG
DOOR
NON-POWER
ZONE
BR/WT
40
39
CAM L1
LOCK
PANEL
BR/WT
BLK
RD
RD
BN
BN
WT
BK
BK
BK
BN
BN
WT
PMG
BK
BK/WT
BK
BK
BR/WT
40
39
BR/WT
BN
BK
WT
TO L2
BK
BK
BN
YL
TO L3
BN/WT
OR
WT
GN/YL
RD
CAM LOCKS
43
RPM IN
RPM GND
GEN VOLTAGE
L2
L3
N
PHASE B VOLTAGE
PHASE C VOLTAGE
L3
PHASE C CURRENT
PHASE GND
BO1 START
C1 +12VDC
BO5
BO6
BO7
BO3
BO4
BO2 FUEL
C2 +12VDC
L
COM
ECU H
ECU L
ECU COM
PLUG LOCATION
LEFT SIDE
PIN
LOCATION
BI2
BI3
BI4
BI5
BI6
BI7
REMOTE START
LOW COOLANT
RECONNECT DOOR
OPEN
OPEN
OPEN
3 PIN PLUG
BI1
PIN
LOCATION
E STOP
PLUG LOCATION
LOWER
BO1
SRT
BO2
FUE
OPEN
OPEN
OPEN
OPEN
OPEN
POWER - DC
D+
D+
PIN
LOCATION
POWER + DC
PLUG LOCATION
LOWER
RELAY BOARD
L2
PHASE B CURRENT
COM
L1
PIN
LOCATION
PHASE A CURRENT
PLUG LOCATION
UPPER
NEUTRAL
L1
PLUG LOCATION
UPPER
PHASE A VOLTAGE
PIN
LOCATION
COM
COMMON
FUEL IN
AI1
AI2
AI3
PIN
LOCATION
WATER IN
OIL IN
PLUG LOCATION
LOWER
ANALOG INPUTS
MAG REF
BK
GY/OR
GY/BK
GY
BK
GY
GY
RD/VI2
RD/BK
RD/YL
RD/WT
BK
L1
L2
L3
600V UNITS
ONLY
L0
L3
L2
L1
VOLTAGE
SENSE
TRANSFORMER
RD/BK
L2
L1
TB
WT
YL
SHIELD
REMOTE START
CONTACTS
BK
CONTROL
POWER
SWITCH
MAIN
BREAKER
L3
L0
OR
BN
YL
TO 4 POS PHASE
SWITCH IF EQUIPPED
RD/BK
GN
OR/WT
YL/WT
BN/WT
OR
WT
BN
YL
WT/VI
3
4
SHUNT
PIN
LOCATION
RD/WT
WT
WT
WT
CT-3
CT-2
CT-1
SPLICE
SPLICE
BK
BK
BK
WT
OR
CAN-L
21-PIN U
DEUTSCH
CAN-H
22
21
FUEL
LEVEL
DEUTSCH
21-PIN J
ALT. EXCITE
NC
DEUTSCH
21-PIN G
"RUN"
DEUTSCH
21-PIN V
21-PIN F
CAN-SHLD
DEUTSCH
GN
TO GND BAR
GROUND
TO TANK
LOW
COOLANT
F-
GEN
F+
TO
GEN FIELD
GEN
F-
F+
TO
VOLTAGE
REGULATOR
NO
E-STOP
SWITCH
14
13
13
14
E-STOP
SWITCH
NO
NC
24
11 NO 12
23
RECONNECT
DOOR SW
FOR
MMG235
ONLY
GROUND TO
ENGINE BLOCK
BK
87
CONN1
RD/YL
30
STARTER
RELAY
12 V
BATTERY
RD
FOR
MMG320
ONLY
OR
BK
MAG IN
10
34
12
33
11
MJB
BR/WT
ALT
RD
TO GND
BAR
TO GND
BAR
BK
BK/WT
RD/BK
CONN2
BK/WT
BK/WT
SEE APPROPRIATE
AC PRINT
90227_D_10.01.13
OPTIONAL
HEATED
FUEL
FILTER
STARTER
RD/WT
RPM
BK
RD
RD/WT
PLUG LOCATION
LOWER
SHLD
SHLD
CLR
CLR
BK
BK
OR
OR
RD/VI 1
RD/VI
VIO
WT/VI
WT/VI
GY/BK
GY/BK
BK
BK
BK
BK
RD
RD
GY
GY
GN/YL
GN/YL
OR
OR
RD/WT
RD/WT
BR/WT4
BN/WT
GY
GY
BK/WT
BK/WT
BK
BK
BN/WT3
BN
BK
RD
RD
RD
RD
85
86
BK
87A
YL
OR
OR
RD
RD
RD
15A
BK
RD/WT
G
E
D
B
X
W
V
U
T
S
R
P
N
M
L
K
J
H
F
C
44
A
MDC CONTROLLER
DC WIRING DIAGRAM
RD/VI
30
87A
85
OR
22
23
31 PIN
DEUTSCH
CONN-2
OR
31 PIN
21
20
DEUTSCH
CONN-2
21 PIN
TO GND
BAR
TO
GY/OR CONT
BO7
MTB PIN 1
(FUEL)
OR
ESTOP ON UNITS UP TO MMG55
86
87
GY/OR
RD/BK
BK
21 PIN
DEUTSCH
CONN-2
DOOR SWITCH
LIGHT SWITCH
RD/BK
INTERIOR
CABINET
LIGHT
FAN
CLUTCH
RELAY
FAN
CLUTCH
INTERIOR
LIGHT 1
FAN
CLUTCH
BK/WT
GY/OR
INTERIOR
LIGHT 2
PANEL LIGHT
RD/BK
BK
4 DOOR
FLIPHOOD
PANEL LIGHT
MTB
10 OR 12 POS
FUSED POWER
LIGHT ENABLE
SWITCH
MAIN POWER
SWITCH
BK/WT
85
87
30
87A
86
RD/VI
FUEL HEAT
RELAY
MTB
86
RD/WT
NC
BI4
RD/YL
SOLAR BATTERY
CHARGER
2A FUSE
BLK
RED
12 V
BATTERY
HIGH IDLE
CONN-2
DEUTSCH
21 PIN
LEAK
DETECT
?
MAY
VARY
31 PIN
MTB RD/OR
300 OHM
1.3K OHM
21 PIN
FILTER
HEATER
ESTOP
22
CONN-2 CONN-1
DEUTSCH DEUTSCH
CHARGE
MODULE
85
OR
BK/WT
RD/BK
HEATED
FUEL
FILTER
MMG 405
& 465 ONLY
MTB
31 PIN
CONN-2
21 PIN
CONN-2
24
25
RD/VI
87A
30
BK/WT
TO GND
BAR
87
HIGH IDLE
RELAY
BK/YL
SOLAR
PANEL
BO6
BO3
BO4
BO5
PIN
LOCATION
4 PIN PLUG
BINARY OUT
FLOAT
RD SWITCH RD SPLICE
RD/BK
TO GND
BAR
10
RD/WT
OR
BK
BK
BK
BK
RD
NO
COM
NO
BOTTOM
BO6
BO3
BO4
BO5
LOCATION
BI1
BI2
BI3
BI4
BI5
BI6
PIN
LOCATION
E STOP
OPEN
FUEL XFER
OPEN
OPEN
3
COM
NO
WT
REMOTE COMMUNICATION
RELAY BOARD
2 3 4 5
COM
GRY/VIO
GRY/VIO
85
87
8
MTB
30
87A
86
RED/WHT
FUEL XFER
RELAY
RED/VIO
FUEL TRANSFER
ENABLE SW
BLK/WHT
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
BI2
BO7
BO6
BO5
BO4
+
D+
PLUG
LABEL
RELAY BOARD
WT 6
WT 4
25A FUSE
WT 8
CONTROL
PANEL
LIGHT
WT 12
MTB
10 OR 12 POS
FUSED POWER
CONN-2
DEUTSCH
14
13
G
OR
31 PIN
21 PIN
FUEL
TRANSFER
PUMP
90416_K_06.27.13
FUEL
TRANSFER
PUMP
TO GND
BAR
BLK/WHT
TO GND
BAR
BLK
12 V
BATTERY
BATTERY
DISCONNECT
12 V
BATTERY
16/3
BATTERY
CHARGER
BATTERY
DISCONNECT
BATTERY
CHARGER
BLU
YEL/GRN
BRN
EDISON PLUG
RED
+
WT
BLK
45
SPLICE
AMBER
MARKER
LAMP
AMBER
MARKER
LAMP
AMBER
MARKER
LAMP
AMBER
MARKER
LAMP
FENDER
FENDER
RED
MARKER
LAMP
IDENTIFICATION
LIGHT BAR
RED
MARKER
LAMP
PLATE
LAMP
STOP-TURN
SIGNAL LAMP
(LEFT)
STOP-TURN
SIGNAL LAMP
(RIGHT)
90386_ORG_05.23.12
46
WHT
BLU
SWITCH
BREAKAWAY
BLK
BATTERY
WHT
BLU
WHT
BLU
BRAKE
BLU
WHT
BRAKE
BLU
WHT
BRAKE
BLU
BRAKE
BLU
TRI-AXLE
BLU
BLU
TANDEM AXLE
WHT
BLU
WHT
90286_D_10.31.12
SINGLE AXLE
BLU
WHT
WHT
BRAKE
BLU
WHT
WHT
WHT
BLU
WHT
WHT
BRAKE
47
SERVICE LOG
OIL GRADE: _____________________________________ BRAND:___________________________________
COOLANT MIXTURE: ______________________________ BRAND:___________________________________
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48
NOTES
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49
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50
REV: ORG
PART NO: 31063
10.11.13