Generac Power Systems MAGNUM MMG75D, MAGNUM MMG100D Operating Manual

DIESEL GENERATOR
MMG75D • MMG100D
TM
With Controller
01886
OPERATING MANUAL
Parts manuals available online at www.generacmobile.com
33701 C 02/16
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. (000004)
WARNING
CALIFORNIA PROPOSITION 65 WARNING: This product contains or emits chemicals known to the state of California to cause cancer, birth defects, and other reproductive
harm. (000005)
WARNING
ENVIRONMENTAL HAZARD: Always recycle batteries at an official recycling center in
accordance with all local laws and regulations. Failure to do so could result in
environmental damage, death or serious injury. (000228)
Introduction
This manual provides information and procedures to safely operate and maintain the Generac Mobile Products 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 Generac Mobile Products, or can be found at www.generacmobile.com.The information contained in this manual
was based on machines in production at the time of publication. Generac Mobile Products reserves the right to change any portion of this information without notice.
Read all of the manuals included with the unit. Each manual details specific information regarding items such as setup, use and service requirements. An engine operator’s manual provides detailed operation and maintenance procedures for the engine. Additional copies of the engine operator’s manual are available from the engine manufacturer.
DO NOT MODIFY or use this equipment for any application other than for which it was designed.
Only a trained and licensed electrician should perform wiring and connections to unit. Wiring must be in compliance with National Electrical Code (NEC), state and local regulations, as well as Occupational Safety and Health Administration (OSHA) guidelines.
GENERAC MOBILE PRODUCTS LLC
215 Power Drive • Berlin, WI 54923
U.S.A.
Phone: 920-361-4442
FAX: 920-361-4416
Toll Free: 1-800-926-9768
www.generacmobile.com
For technical or parts QUESTIONS, please contact the Generac Mobile Products Customer Support
or Technical Support team at 1-800-926-9768. Please have your serial number available.
To ORDER SERVICE PARTS, please contact the dealer from which you purchased the unit, or call
Generac Mobile Products to locate a dealer in your area.
Engine Make:__________________________________________ Engine Serial Number:___________________________________ Engine Model Number: __________________________________ Generator Make: _______________________________________ Generator Model Number: ________________________________ Generator Serial Number: ________________________________ Unit Model Number:_____________________________________ Unit Serial Number: _____________________________________
iii
This Page Intentionally Left Blank
iv

Table of Contents

Section 1 - Safety
Safety Notes ....................................................................................................................................... 1
Operating Safety................................................................................................................................. 1
Engine Safety ..................................................................................................................................... 2
Service Safety .................................................................................................................................... 2
Towing Safety..................................................................................................................................... 3
Reporting Trailer Safety Defects ........................................................................................................ 3
Safety Symbol Summary .................................................................................................................... 4
Section 2 - General Information
Specifications ..................................................................................................................................... 5
Unit Dimensions .................................................................................................................... 7
Unit Serial Number Locations............................................................................................................. 8
Component Locations......................................................................................................................... 9
Control Panel.................................................................................................................................... 10
Power Zone™ Gen Controller .......................................................................................................... 11
Controller Features and Functions ......................................................................................11
Maintenance Screens.......................................................................................................... 14
Generator Monitoring........................................................................................................... 18
Engine Monitoring................................................................................................................ 18
Diesel Exhaust Filter Monitoring.......................................................................................... 18
Controller Information Displays, Functions, and Reset ....................................................... 19
Belt Tensioners................................................................................................................................. 20
Front Hood Operation....................................................................................................................... 20
To Open the Front Hood...................................................................................................... 20
To Close the Front Hood .....................................................................................................21
Section 3 - Operation
Prestart Checklist ............................................................................................................................. 23
Manually Starting the Unit ................................................................................................................ 23
Auto (Remote) Starting the Unit ....................................................................................................... 24
Transfer Switch................................................................................................................................. 25
Derating for Altitude.......................................................................................................................... 26
Generator Output Connections......................................................................................................... 27
Fine Voltage Adjustment .................................................................................................................. 27
Voltage Selector Switch.................................................................................................................... 28
Voltage Regulator............................................................................................................................. 29
Customer Convenience Receptacles ............................................................................................... 30
Main Circuit Breaker ......................................................................................................................... 30
Exhaust Filter Cleaning Operations.................................................................................................. 31
Disabling Automatic (Auto) Exhaust Filter Cleaning............................................................ 31
Force a Manual Exhaust Filter Cleaning ............................................................................. 31
Enable Exhaust Filter Cleaning ...........................................................................................32
Auto Exercise Timer ......................................................................................................................... 32
Accessing the Configuration Menu...................................................................................... 32
Set the Controller Clock....................................................................................................... 32
Set the Schedule ................................................................................................................. 32
Set the Unit to Auto Mode ................................................................................................... 33
Shutting Down the Unit..................................................................................................................... 33
Emergency Stop Switch ................................................................................................................... 34
ECU Override Switch........................................................................................................................ 34
Towing the Unit................................................................................................................................. 34
Lifting the Unit................................................................................................................................... 35
v
Section 4 - Maintenance
Emissions Information ...................................................................................................................... 37
Daily Walk Around Inspection........................................................................................................... 37
General Maintenance ....................................................................................................................... 37
Basic Maintenance Schedule ........................................................................................................... 38
Engine Break-In Requirements ........................................................................................................ 39
Resetting the Maintenance Alarms................................................................................................... 39
Exhaust Filter Service Requirements ............................................................................................... 40
Checking Generator Drive Plate Torque .......................................................................................... 40
Jack Maintenance............................................................................................................................. 41
Side-Wind Models ............................................................................................................... 41
Top-Wind Models ................................................................................................................ 41
Trailer Wheel Bearings ..................................................................................................................... 41
Section 5 - Troubleshooting
General Troubleshooting .................................................................................................................. 43
Section 6 - Wiring Diagrams
AC Wiring - 3 Position Voltage Selector Switch ............................................................................... 45
AC Wiring - 4 Position Voltage Selector Switch Option.................................................................... 46
AC Wiring Options ............................................................................................................................ 47
PMG Wiring Option........................................................................................................................... 48
DC Wiring ......................................................................................................................................... 49
DC Wiring Options............................................................................................................................ 50
Low Oil Level Wiring Option ............................................................................................................. 51
Battery Charger Wiring Option ......................................................................................................... 51
Engine Heater Wiring Option............................................................................................................ 51
Wiring Block Diagram - Dedicated 12 Lead Generators Option ....................................................... 52
Trailer Lights Wiring.......................................................................................................................... 53
Wiring Harness - Electric Brake Option ............................................................................................ 54
Section 7 - Options & Accessories
Viscous Fan Clutch Option ............................................................................................................... 55
Generator Cam Lock Connections Option........................................................................................ 55
Service Log ............................................................................................................................ 57
vi

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.
INDICATES A HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN
Indicates a hazardous situation which, if not avoided, could result in death or serious
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
Section 1 - Safety
DANGER
DEATH OR SERIOUS INJURY.
WARNING
injury.
CAUTION
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 unit, 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 unit. The following points should be practiced at all times:
The area immediately surrounding the unit should be dry, clean, and free of debris.
Position and operate the unit on a firm, level surface.
DO NOT start a unit in need of repair.
If the unit is equipped with a frame grounding stud, follow any local, state, and National Electrical Code (NEC) guidelines when connecting.
DO NOT operate the unit on a combustible surface.
DO NOT operate a unit while tired, distracted, or under the influence of drugs or alcohol.
Keep all body parts, clothing and other loose items away from moving parts.
DO NOT fill fuel tank near an open flame, while smoking, or while engine is running. DO NOT fill tank in an enclosed area with poor ventilation.
DO NOT operate with the fuel tank cap loose or missing.
Shut the engine down if any of the following conditions exist during operation:
33701 C MMG75D-100D Operating Manual 1
Safety
1. Noticeable change in engine speed.
2. Loss of electrical output.
3. Equipment connected to the unit overheats.
4. Sparking occurs.
5. Engine misfires or there is excessive engine/generator vibration.
6. Protective covers are loose or missing.
7. If the ambient air temperature is above 120°F (49°C).

ENGINE SAFETY

Internal combustion engines present special hazards during operation and fueling. Failure to follow the safety guidelines described below could result in severe injury or death. Read and follow all safety warnings described in the engine operator's manual. A copy of this manual was supplied with the unit when it was shipped from the factory.
DO NOT run engine indoors or in an area with poor ventilation unless exhaust hoses are used. Engine exhaust contains carbon monoxide, a deadly, odorless and colorless gas which, if inhaled, can cause nausea, fainting or death. Make sure engine exhaust cannot seep into closed rooms or ventilation equipment.
DO NOT touch or lean against hot exhaust pipes or engine components.
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.
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.
DO NOT open the radiator cap or oil drain plug while the engine is running or before the engine has cooled down. Pressurized coolant and hot engine oil can cause severe burns. Allow the unit to cool completely before attempting any service work.
Keep area around exhaust pipes and air ducts free of debris to reduce the chance of an accidental fire.

SERVICE SAFETY

All service work must be performed by qualified personnel who are familiar with the equipment. Only a qualified electrician should troubleshoot or repair electrical problems occurring in this equipment. Fol­low the safety guidelines described below to prevent hazardous situations which could result in severe injury or death.
NEVER wash the unit with high pressure hoses, power washers, or steam cleaners. Water may collect in the unit, causing damage to electrical parts.
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.
Replace all missing and hard to read decals. Decals provide important operating instructions and warn of dangers and hazards.
Before servicing the unit, verify the Control Power switch and circuit breakers are in the OFF (O) position, and the negative (-) terminal on the battery is disconnected. DO NOT perform even routine service (oil/filter changes, cleaning, etc.) unless all electrical components are shut down.
2 MMG75D-100D Operating Manual 33701 C
DO NOT start the unit under load. The circuit breakers must be in the OFF (O) position when starting the unit in Manual mode. The circuit breakers can be in the ON (I) position only when started in the Auto mode. A transfer switch must be used in the Auto mode to deflect the load upon startup.

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. 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.
Verify the hitch and coupling on the towing vehicle are rated equal to, or greater than, the trailer's Gross Vehicle Weight Rating (GVWR).
Check trailer tires for wear and proper inflation.
DO NOT tow trailer using defective parts. Inspect the hitch and coupling for wear or damage.
Verify the trailer hitch and the coupling are compatible. Make sure the coupling is securely fastened to the vehicle.
Verify directional and brake lights on the trailer are connected and working properly.
Verify wheel lug nuts are present and tightened to the specified torque.
Maximum recommended speed for highway towing is 45 mph (72 km/h). Recommended off-road towing speed is 10 mph (16 km/h) or less, depending on terrain.
Safety
When towing, maintain extra space between vehicles and avoid soft shoulders, curbs and sudden lane changes. Practice turning, stopping and backing up in an area away from heavy traffic prior to transporting the unit.
Wipe the coupler clean and apply fresh grease each time the trailer is towed to eliminate squeaking.
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.
Before towing the trailer, verify that the weight of the trailer is equal across all tires. On trailers with adjustable height hitches, adjust the angle of the trailer tongue to keep the trailer as level as possible. On units equipped with a tandem axle trailer, a large angle between the trailer and tow vehicle will cause more weight to be carried by one axle, which could cause premature wear on the tires and axles and cause potentially unsafe operating conditions.
The trailer is equipped with hydraulic or electric surge brakes. Verify proper 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, verify the level in the brake fluid reservoir, if equipped.

REPORTING TRAILER SAFETY DEFECTS

If you believe your trailer has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Generac Mobile Products LLC.
If NHTSA receives similar complaints, it may open an investigation; and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in an individual problem between you, your dealer, or Generac Mobile Products LLC.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-888-327-4236 (TTY:1-800-424-9153), go to http://www.safercar.gov; or write to:
Administrator NHTSA 1200 New Jersey Avenue S.E. Washington, DC 20590
33701 C MMG75D-100D Operating Manual 3
Safety
You can also obtain other information about motor vehicle safety from http://www.safercar.gov.

SAFETY SYMBOL SUMMARY

The safety and operating decals affixed to the unit provide important 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 online parts manual at www.generacmobile.com. 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.
Hot surface(s) nearby.
Belt/entanglement hazard; keep body parts clear of this area.
Fan hazard; keep body parts clear of this area.
Never change switch position while engine is running.
Stop engine before making connections.
Stop engine before fueling.
Asphyxiation hazard; operate in well ventilated area.
Dangerous voltage may be present.
Anchor/tie down point.
Isolate generator to prevent electrocution hazard.
Use clean diesel fuel only.
Remove negative battery cable before performing any service on unit.
Read and understand the supplied operator’s manual before operating unit.
Hearing protection required while operating unit with doors open.
Lift here only.
Engine running.
Exhaust Filter Cleaning enabled.
Figure 1-1. Safety Symbol Summary
4 MMG75D-100D Operating Manual 33701 C
Unit electrical ground.
Fire/explosion hazard; keep open flames away from unit.
Burn/scald hazard; pressurized steam.
Exhaust Filter Cleaning disabled.
00383
Section 2 - General Information

SPECIFICATIONS

GENERAC MODEL MMG75D MMG75D Super Start
Engine
Make/Brand............................................................................. John Deere..............................John Deere
Model ......................................................................................PE4045HFG92........................ PE4045HFG92
EPA Tier ..................................................................................4i ............................................. 4i
Horsepower - Prime hp (kW) .................................................97 (72) ..................................... 97 (72)
Horsepower - Standby hp (kW) .............................................107 (80)...................................107 (80)
Operating Speed rpm .............................................................1800 ........................................1800
Displacement in
Cylinders - qty .........................................................................4 ..............................................4
Fuel Consumption - 100% Prime gph (Lph) .........................4.78 (18.1) ...............................4.78 (18.1)
Battery Type - Group Number ................................................. 24 ............................................24
Battery Voltage (quantity per unit)...........................................12V (1) .................................... 12V (1)
Battery Rating .........................................................................720 CCA.................................. 720 CCA
Generator
Make/Brand............................................................................. Marathon Electric ....................Marathon Electric
Model ......................................................................................361PSL1602 ...........................363PSL1607
Type, Insulation....................................................................... Brushless, H ............................ Brushless, H
Generator Set (Engine/Generator)
3Ø - Standby kW (kVA) ..........................................................69 (86) .....................................70 (88)
Amps - 3Ø Standby 480V (208V) A........................................103 (239)................................. 106 (244)
3Ø - Prime kW (kVA) ..............................................................62 (77) ..................................... 63 (79)
Amps - 3Ø Prime 480V (208V) A............................................ 93 (214) ................................... 95 (219)
1Ø - Standby kW (kVA) ..........................................................60 (60) .....................................66 (66)
Amps - 1Ø Standby - 240V A .................................................250 ..........................................275
1Ø - Prime kW (kVA) ..............................................................56 (56) ..................................... 60 (60)
Amps - 1Ø Prime - 240V A .....................................................233 ..........................................250
Frequency Hz.......................................................................... 60 ............................................60
Power Factor........................................................................... 1 (1Ø), 0.8 (3Ø) ....................... 1 (1Ø), 0.8 (3Ø)
Sound dB(A) 23 ft @ prime ...................................................68 ............................................68
3
(L) ..............................................................274 (4.5) .................................. 274 (4.5)
Weights
Dry Weight, Skid Mounted lbs (kg).........................................3530 (1600) .............................3860 (1750)
Operating Weight, Skid Mounted lbs (kg) ..............................4700 (2131) ............................ 5040 (2286)
Dry Weight, Trailer Mounted* lbs (kg) ....................................4240 (1923) ............................. 4570 (2073)
Operating Weight, Trailer Mounted* lbs (kg) .......................... 5410 (2454) .............................5750 (2608)
*Standard trailer only. Consult factory for custom trailer weights.
Capacities
Fuel Tank Volume gal (L)........................................................165 (625) ................................. 165 (625)
Usable Fuel Volume gal (L)....................................................151 (572) ................................. 151 (572)
Coolant (incl. engine) qt (L) ....................................................22.0 (20.8)...............................22.0 (20.8)
Oil (incl. filter) qt (L) ................................................................15.5 (14.7)...............................15.5 (14.7)
Maximum Run Time hrs .........................................................31 ............................................31
AC Distribution
Circuit Breaker Size ................................................................300 ..........................................300
Voltage Selection ....................................................................3 position switch (lockable) .....3 position switch (lockable)
Voltage Regulation..................................................................+/- 0.5%...................................+/- 0.5%
Voltages Available 1Ø .............................................................120, 139, 208, 220, 240, 277 ..120, 139, 208, 220, 240,
Voltages Available 3Ø .............................................................208, 220, 440, 480 ..................208, 220, 440, 480
Trailer
Number of Axles......................................................................1 ..............................................1
Capacity - Axle Rating lbs (kg)............................................... 6000 (2722) ............................. 6000 (2722)
Tire Size in
Brakes.....................................................................................Surge....................................... Surge
Hitch - Standard ......................................................................3'' ring......................................3'' ring
Maximum Tire Pressure psi....................................................65 ...........................................65
..............................................................................15 ............................................15
277
33701 C MMG75D-100D Operating Manual 5
General Information
GENERAC MODEL MMG100D MMG100D Super Start
Engine
Make/Brand............................................................................. John Deere..............................John Deere
Model ......................................................................................PE4045HFG92........................ PE4045HFG92
EPA Tier ..................................................................................4i ............................................. 4i
Horsepower - Prime hp (kW) .................................................121 (90) ................................... 121 (90)
Horsepower - Standby hp (kW) .............................................133 (99)...................................133 (99)
Operating Speed rpm .............................................................1800 ........................................1800
Displacement in
Cylinders - qty .........................................................................4 ..............................................4
Fuel Consumption - 100% Prime gph (Lph) .........................6.2 (23.5) .................................6.2 (23.5)
Battery Type - Group Number ................................................. 24 ............................................24
Battery Voltage (quantity per unit)...........................................12V (1) .................................... 12V (1)
Battery Rating .........................................................................720 CCA.................................. 720 CCA
Generator
Make/Brand............................................................................. Marathon Electric ....................Marathon Electric
Model ......................................................................................362PSL1606 ...........................363PSL1607
Type, Insulation....................................................................... Brushless, H ............................ Brushless, H
Generator Set (Engine/Generator)
3Ø - Standby kW (kVA) ..........................................................86 (107) ...................................88 (110)
Amps - 3Ø Standby 480V (208V) A........................................129 (297)................................. 132 (305)
3Ø - Prime kW (kVA) ..............................................................78 (98) ..................................... 80 (100)
Amps - 3Ø Prime 480V (208V) A............................................ 118 (272) ................................. 120 (278)
1Ø - Standby kW (kVA) ..........................................................75 (75) .....................................78 (78)
Amps - 1Ø Standby - 240V A .................................................313 ..........................................325
1Ø - Prime kW (kVA) ..............................................................71 (71) ..................................... 72 (72)
Amps - 1Ø Prime - 240V A .....................................................296 ..........................................300
Frequency Hz.......................................................................... 60 ............................................60
Power Factor........................................................................... 1 (1Ø), 0.8 (3Ø) ....................... 1 (1Ø), 0.8 (3Ø)
Sound dB(A) 23 ft @ prime ...................................................68 ............................................68
3
(L) ..............................................................275 (4.5) .................................. 275 (4.5)
Weights
Dry Weight, Skid Mounted lbs (kg).........................................3780 (1714) .............................3930 (1782)
Operating Weight, Skid Mounted lbs (kg) ..............................4740 (2150) ............................ 4890 (2218)
Dry Weight, Trailer Mounted* lbs (kg) ....................................4480 (2032) ............................. 4630 (2100)
Operating Weight, Trailer Mounted* lbs (kg) .......................... 5440 (2467) .............................5590 (2535)
*Standard trailer only. Consult factory for custom trailer weights.
Capacities
Fuel Tank Volume gal (L)........................................................165 (625) ................................. 165 (625)
Usable Fuel Volume gal (L)....................................................151 (572) ................................. 151 (572)
Coolant (incl. engine) qt (L) ....................................................22.0 (20.8)...............................22.0 (20.8)
Oil (incl. filter) qt (L) ................................................................15.5 (14.7)...............................15.5 (14.7)
Maximum Run Time hrs .........................................................24 ............................................24
AC Distribution
Circuit Breaker Size ................................................................400 ..........................................400
Voltage Selection ....................................................................3 position switch (lockable) .....3 position switch (lockable)
Voltage Regulation..................................................................+/- 0.5%...................................+/- 0.5%
Voltages Available 1Ø .............................................................120, 139, 208, 220, 240, 277 ..120, 139, 208, 220, 240,
277
Voltages Available 3Ø .............................................................208, 220, 440, 480 ..................208, 220, 440, 480
Trailer
Number of Axles......................................................................1 ..............................................1
Capacity - Axle Rating lbs (kg)............................................... 6000 (2722) ............................. 6000 (2722)
Tire Size in.............................................................................. 15 ............................................15
Brakes.....................................................................................Surge....................................... Surge
Hitch - Standard ......................................................................3'' ring......................................3'' ring
Maximum Tire Pressure psi....................................................65 ...........................................65
Specifications are subject to change without notice.
6 MMG75D-100D Operating Manual 33701 C

Unit Dimensions

General Information
C
A
B
C
A
B
01887
Figure 2-1. Unit Dimensions
A (Width) B (Length) C (Height)
MMG75D/100D - Skid Mounted 40 in. (1.02 m) 119 in. (3.02 m) 62 in. (1.57 m)
MMG75D/100D - Trailer Mounted 69 in. (1.75 m) 170 in. (4.32 m) 80 in. (2.03 m)
Specifications are subject to change without notice.
33701 C MMG75D-100D Operating Manual 7
General Information

UNIT SERIAL NUMBER LOCATIONS

See Figure 2-2 for 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.
UNIT ID Tag
Manufactured by Generac Mobile Products LLC.
(920) 361-4442 (800) 926-9768
Model
Country of Origin
Manufacturing Code
Weight (lbs/kg) RPM/Frequency
1 ph. 1.0PF 3 ph. .8PF 3 ph. 1.0PF
KW
KVA
V
A
Located on control panel
Serial Number
Rating
Ins. Class
FOR ELECTRICAL EQUIPMENT
ONLY. POUR MATERIAL
ELECTRIQUE SEULEMENT.
209649
Form: SFC626B
VIN Tag
MANUFACTURED BY/FABRIQUE PAR: GeneracMobile Products LLC DATE: 00/0000 GVWR/PNBV: 000KG (0000LBS) COLD INF. PRESS./ PRESS. DE
GAWR / PNBE TIRE / PNEU RIM / JANTE GONF A FROID - KPA(PSI/LPC) SGL / DUAL
EACH AXLE
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.
00000000000000000
V.I.N./N.I.V.:
Figure 2-2. Serial Number Locations
MODEL:
TYPE:
TRAILER
XXX000
TIRE AND LOADING INFORMATION
RENSEIGNEMENTS SUR LES
The weight of cargo should never exceed 0000KG (0000LBS) Le poids du chargement ne doit jamais depasser 0000KG (0000LBS)
PNEUS ET LE CHARGEMENT
SEE OWNER’S MANUAL FOR
INFORMATION
RENSEIGNEMENTS
ADDITIONAL
VOIR LE
MANUEL DE
L’USAGER
POUR
PLUS DE
02070
8 MMG75D-100D Operating Manual 33701 C

COMPONENT LOCATIONS

General Information
1
13
14
15
2
3
4
5
6
8
9
10
12
11
Figure 2-3. Component Locations
1. Central lift point 9. Oil drain port
2. Voltage selector switch access 10. Fuel fill
3. Generator access 11. Control panel access
4. Manual holder access 12. Emergency stop switch
5. Engine exhaust 13. Handle
6. Front hood latch 14. Radiator access
7. Engine/battery access 15. Engine access
8. Radiator drain port
7
01889
33701 C MMG75D-100D Operating Manual 9
General Information

CONTROL PANEL

14
13
1
2
12
11
10
3
4
5
86
79
01890
Figure 2-4. Control Panel Component Locations
1. Power Zone™ controller 8. Cam lock connections (5)
2. 50A circuit breakers (3) 9. Generator ground connection lug
3. 120V GFCI receptacles (2) 10. Generator output connection lugs (4)
4. 20A circuit breakers (2) 11. Door safety switches (2)
5. Remote start terminal block 12. Diesel exhaust filter cleaning switch
6. Engine accessory connection (2) 13. Auxiliary light switches (optional)
7. 120/240V twist-lock receptacles (3) 14. Main circuit breaker
10 MMG75D-100D Operating Manual 33701 C
General Information
CONTROL
ON
CONTROL
OFF
I
O
CONTROL
ON
CONTROL
OFF
I
O

POWER ZONE™ GEN CONTROLLER

The Power Zone™ controller is an auto start controller that monitors the unit and indicates operational status and fault conditions. The controller can be programmed to automatically start or stop, based on time schedule, fault condition, or load demand.
The controller constantly monitors vital generator and engine functions for a number of preprogrammed alarm and fault conditions. When a fault condition occurs, the engine can be shut down automatically and the LCD window will show the fault that caused the shut down; to resume operation, the fault condition must be resolved.
This controller also records a history of unit performance which may be viewed at any time and will not be lost when the controller is powered down.
e
C
n
o
o
n
t
r
o
l
l
e
r
STARTING THE GENERATOR
DAS STARTEN DES GENERATORS COMIENZO DEL GENERADOR COMMENCEMENT DU GÉNÉRATEUR
1. PRESS CONTROL POWER
SWITCH “ON”
2. PUSH ENGINE START “I”
CONTROL ON
I
CONTROL
ON
1
CONTROL
OFF
2
O
CONTROL OFF
STOPPING THE GENERATOR
DAS AUFHÖREN DES GENERATORS PARADA DEL GENERADOR ARRÊT DU GÉNÉRATEUR
1. PUSH ENGINE STOP “O”
2. PRESS CONTROL POWER
SWITCH “OFF”
CONTROL
ON
CONTROL
OFF
11
10
Z
r
e
w
o
P
9
8
7
6
5
4
3
01780
Figure 2-5. Power Zone™ Controller Layout
1. Navigation buttons 7. Alarm mute button
2. Control power switch 8. Voltage Adjust button
3. Engine start button 9. Generator button
4. Engine stop/reset button 10. Engine button
5. Liquid Crystal Display (LCD) 11. Home button
6.
Auto/manual mode button

Controller Features and Functions

Home Button
The Home ( ) button is the default screen of the controller and will display after the controller is powered up and the unit management software is loaded. It displays a live readout of the kW meter, percent of load used (gauge), selected phase, volts and amps being produced by the generator, and the fuel level with time until empty. The controller will automatically return to this screen from any other screen after a period of inactivity.
33701 C MMG75D-100D Operating Manual 11
General Information
Manual Mode
Time to Empty
15 hr
110
100
106.9 kW
GEN
V
-
+
60
50
40
30
20
10
0
90
80
70
%
3 PHASE
Volts
480
Amps
128
Figure 2-6. Home Button Screen
Engine Button
The Engine ( ) button 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 task, along with the description of the maintenance procedure and the action that will take place when the timer trips the alarm.
Full
3/4
1/2
1/4
Empty
74
%
00393
Manual Mode
40 60
20
0
GEN
Oil press. Coolant Temp. Battery
V
-
+
Maintenance
Alarm Hours Description Action
1 174 To Service Oil Maintenance 2 174 To Service Fuel Maintenance 3 174 To Service Air Maintenance
80
100
190 210
170
230
250
°F214PSI50.9
0 0 3 2 5 1 5
Hrs
10
0
20 30
13.8 V
Electrical Trip
Warning
Shutdown
40
50150
00394
Figure 2-7. Engine Button Screen
Note: If the measured value is outside the range of a gauge, the needle will not be displayed. The digital value below the gauge will still show the measured value.
Oil Press: Displays engine oil pressure. Current coolant temperature is displayed directly below the gauge at all times. The gauge registers oil pressure between 0-100 psi (0-689 kPa). Normal operating pressure is between 35-80 psi (241-552 kPa).
Coolant Temp: Displays engine coolant temperature. Current coolant temperature is displayed directly below the gauge at all times. The gauge displays coolant temperature between 150°-250°F (66°-121°C). Normal operating temperature of the unit is between 180°-200°F (82°-93°C) with an average ambient air temperature of 70°F (21°C).
Battery: Displays the engine battery voltage. Current battery voltage is displayed directly below the gauge at all times. The gauge displays battery voltage between 0-50V. A normal reading is 12-14V on 12 volt systems and 24-26V on 24 volt systems (with the engine running).
12 MMG75D-100D Operating Manual 33701 C
General Information
V
V
Generator Button
The Generator ( ) button displays the average voltage frequency, volts and amps from the generator, as well as line-to-line voltage and individual line-to-neutral voltage, amperage and power (kW). This screen also displays the generator winding configuration set by the voltage selector switch in the lower right corner.
GEN
Manual Mode
GEN
V
-
+
30 40
20
10
0
Volt Volt Amp kW
L1-L2 L1
L2-L3 L2
L3-L1 L3
Freq
0 0 0
50
70 0
IE
60
0 0 0
175
88
0 25 50
0
263
350 0
Parallel Low Zig-Zag
0.0
0.0
0.0
25
13
L1 (U)
38
50
AmpVolt
N
L2 (W)
00395
Figure 2-8. Generator Button Screen
Note: When loading the generator, it is important to observe the amperage to determine the load balance on each line of the generator. Minor load unbalances, usually ten percent or less, will not cause any particular problems. Every effort should be made to distribute the load equally between all lines.
Freq: Displays the output frequency in Hertz (Hz). Normal operating frequency is 60 Hz.
Volts: Displays the nominal voltage in Volts (V).
Amps: Displays the AC output amperage produced by the generator in Amps (A).
Additional information can be found on the electric power table at the bottom-left side of the screen. This provides an overview of all three lines and average voltage and amperage readouts.
Voltage Adjust Button
V
The Voltage Adjust ( ) button displays the line-to-neutral and line-to-line voltage averages. The operator can
-
+
electronically adjust the voltage within limits to prevent under-voltage or over-voltage conditions using the on-screen instructions. This feature replaces a traditional potentiometer. See Fine Voltage Adjustment for more information.
Manual Mode
Voltage Adjust
- Press , voltage will begin flashing
- Use and arrows to adjust voltage
- Press to confirm new voltage. Numbers will stop flashing
GEN
V
-
+
480 277
L-N Average
L-L Average
00396
Figure 2-9. Voltage Adjust Button Screen
Alarm Mute Button
The Alarm Mute ( ) button silences the audible alarm. Additional action will be required to fully disable the active alarm.
33701 C MMG75D-100D Operating Manual 13
General Information
Auto/Manual Mode Button
The Auto/Manual Mode ( ) button is used to change the startup and shutdown modes of the unit. When pressed once, the unit enters Manual mode and when pressed and held for five seconds, the unit enters Auto mode. If in Auto mode, pressing once will return the unit to Manual mode.
Navigation Buttons
These buttons are used to navigate and interact with the Power Zone™ controller screens. Pressing any directional arrow (▲, ►, ▼, ◄) while on any of the operator screens will open the maintenance screens, and navigate the tabs and pages within the maintenance screens. The Enter () button is used to select menus, confirm alarms, and confirm altered settings.
Control 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 Button
Pressing the Engine Start (I) button while the controller is in Manual mode will start the unit, provided there are no shutdown errors and the engine satisfies the start status. If the controller is in Auto mode, the Engine Start (I) button has no effect.
Engine Stop/Reset Button
Pressing the Engine Stop/Reset (O) button will shut down the unit and put the controller into Stop mode, whether in Manual mode or Auto mode.
CAUTION
In case of an emergency, always press the emergency stop switch located on the side of the unit to stop the engine immediately. The Engine Stop/Reset (O) button may delay the
engine shutdown if stop faults exist.
To prevent damage to the generator and connected equipment, remove all loads from the
generator by opening all circuit breakers (turn OFF (O)) before pressing the Engine Stop/
Reset (O) button.
The Liquid Crystal Display (LCD)
This window will display the various operator and maintenance screens. By viewing these screens, the operator will be able to monitor both the engine and generator status while the unit is running.

Maintenance Screens

All of the data inputs from the engine, generator, inputs/outputs, schedule and Power Zone™ controller are visible on the maintenance screens.
The information displayed on the maintenance screens can be used to identify, diagnose and troubleshoot unit shutdown conditions and poor unit performance. The maintenance screens can be accessed from any operator screen by pressing any directional arrow (, , , ).
The bottom of the screens have a list of available tabs, with the currently displayed tab highlighted in blue. The tabs can be selected by using the or buttons. To the left of the tabs, the current/available pages are displayed. The pages within a tab can be viewed by using the and buttons. Whenever a new tab is selected, the current page will always be page one.
14 MMG75D-100D Operating Manual 33701 C
General Information
Generator Summary
The Generator Summary can be found at the top of all maintenance screens and provides an overview of the system.
SITE GENSET
Return Delay 10:00:00
0.0
Hz
kW
kVAr
Figure 2-10. Generator Summary Screen
Engine Tab
The Engine tab contains maintenance and instrumentation data gathered from the engine. Above the engine analogue meters is a row of alarm icons. Each icon can be one of three colors: gray (inactive), yellow (warning) or red (shutdown). The alarm icons are as follows from left to right: water in fuel, emission filter, engine air inlet temperature, charge alternator, oil pressure, fuel level, battery voltage, coolant temperature, and ECU lamp.
Note: The content may change depending upon the selected engine and the features supported by the engine.
SITE GENSET 7741 \ 7740
Return Delay 10:00:00
kW
12 15
15
GEN
V
-
+
9
6
3
0
0
00000 00
Engine Starts
Fuel Used
Fuel Remaining
1/9
RPM
Hrs
US Gal
Litre
kVAr
18
21
24
27
30
33
36
5
46
3
7
2
1
0
Oil press. Coolant Temp.
100
50 150
0
-50
0 °F V
0.0 Hz
8
9
10 -50
200
250
0.0
0.0
0
10
0
480V/277V 3-Phase
To ta l
0.0
0.0
0.0
%
0.00
%
480V/277V 3-Phase
Total Generator
0.0
0.0
0.0
%
0.0
0.00
%
0.0
100
50 150
200
250 0
0 °FPSI
20 30
40
50
0.0 V0.0
kW
kVA
kVAr
kW
kVA
kVAr
pf
30
20
10
10
0
StatusScheduleI/OAlarmsEngine Generator
Energy Generator
0.0
0.0
0.0
07:10
kWh+
0.0
0.0
kVAh
kVArh
0.0
CAN
50
40 60
70
80
90
100
%
00.00
Fuel Level
20 30
40
50
Charge AltBatteryOil Temp
00398
07:10
kWh+
kVAh
kVArhpf
01781
Figure 2-11. Engine Tab Screen
Generator Tab
The Generator tab contains maintenance and instrumentation data gathered from the generator. Each page highlights different data gathered by the generator, with the analogue meters changing accordingly. The last two pages will display the information in the bar graph. The bar graph shows blue for positive and red for negative. For the power factor bar graph, blue is for lagging pf and red is for leading pf.
Note: The content may change depending upon the selected generator and the features supported by the generator.
33701 C MMG75D-100D Operating Manual 15
General Information
SITE GENSET 7741 \ 7740
Return Delay 10:00:00
0.0 Hz
kW
kVAr
300
400
GEN
V
+
200
100
0
-
L1-L2
L2-L3
L3-L1
1/9
500
600
L1-L2 L2-L3 L3-L1 Hz
Volt Volt Amp kW kVA kVAr pf
L1
0
L2
0
L3
0
IE
300
400
200
100
0
0 0 00
500
600 0
0 0
0
100
200
0.0
0.0
0.0
480V/277V 3-Phase
%
0.0
%
0.0
300
400
500
600 0
0.0
0.0
0.0
Total Generator
kW
0.0
kVA
0.0
kVAr
pf
0.0
30 40
20
10
FreqVoltVoltVolt
70
0.0
0.0
0.0
0.00
0.0
0.0
0.0
StatusScheduleI/OAlarmsEngine Generator
07:10
kWh+
kVAh
kVArh
50
60
0.0
0.0
0.0
00399
Figure 2-12. Generator Tab Screen
Alarms Tab
The Alarms tab displays warnings, electrical trip, shutdown alarms and any engine Diagnostic Trouble Codes (DTC) that are occurring or have occurred previously. The first page on the Alarms tab displays the alarms that are currently active. They are organized by alarm type.
SITE GENSET 7741 \ 7740
Return Delay 10:00:00
0.0 Hz
kW
GEN
Warning Shutdown Electrical Trip
kVAr
480V/277V 3-Phase
%
0.0
%
0.0
Total Generator
kW
0.0
kVA
0.0
kVAr
pf
0.0
0.00
0.0
0.0
0.0
07:10
kWh+
kVAh
kVArh
V
-
+
1/2
Figure 2-13. Alarms Tab Screen (Page One)
Table 1: Diagnostic Trouble Codes
Alarm Type
Warning Yellow/Black
Electrical Trip Purple/Black
Shutdown Red/Black
ECU Code Blue/White
Color -
Background/Text
Engine
StatusScheduleI/OAlarmsEngine Generator
00400
Graphic
Warning
Electrical Trip
Shutdown
Engine
The second page of the Alarms tab shows the event log with a list of events, including normal operation events and alarm notifications, with the most recent events at the top of the list. All indexed events include the date and time of the event, hours of runtime on the engine when it occurred, along with the event name or alarm type and details.
16 MMG75D-100D Operating Manual 33701 C
General Information
SITE GENSET 7741 \ 7740
Return Delay 10:00:00
0.0 Hz
kW
Index Date Time Hrs Event Details 1 01/01/1970 00:00:01 0:00
GEN
2 02/06/1970 11:45:55 0:00 3 01/01/1970 00:00:00 0:00 4 01/01/1970 00:00:00 0:00 5 01/01/1970 00:00:00 0:00
V
-
+
6 01/01/1970 00:00:00 0:00 7 01/01/1970 00:00:00 0:00 8 01/01/1970 00:00:00 0:00 9 01/01/1970 00:00:00 0:00 10 01/01/1970 00:00:00 0:00 11
01/01/1970 00:00:00 0:00 12 01/01/1970 00:00:00 0:00 13 01/01/1970 00:00:00 0:00
2/2
kVAr
Shutdown Shutdown
Warning
Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown
Figure 2-14. Alarms Tab Screen (Page Two)
To scroll down within the event log, press the Enter () button. The scroll bar will change to blue, signifying it is active. Press the or buttons to scroll up or down in the event log. When finished, press the Enter () button again.
Input/Output Tab
The Input/Output (I/O) tab shows a list of digital inputs and outputs connected to the controller, whether they are active and the current state (open/closed status) of the input and output.
SITE GENSET 7741 \ 7740
Return Delay 10:00:00
0.0 Hz
kW
Digital Inputs
Ip Description Active State Ip Description Active State
GEN
A
B
C
V
-
+
D
E
F
kVAr
G
H
I
J
K
480V/277V 3-Phase
Total Generator
kW
0.0
0.0
kVA
kVAr
0.0
%
0.0
0.00
pf
%
0.0
This is an event index 1 This is an event index 2 This is an event index 3 This is an event index 4 This is an event index 5 This is an event index 6 This is an event index 7 This is an event index 8 This is an event index 9 This is an event index 10 This is an event index 11 This is an event index 12 This is an event index 13
480V/277V 3-Phase
Total Generator
kW
0.0
0.0
kVA
kVAr
0.0
%
0.0
0.00
pf
%
0.0
07:10
kWh+
0.0
0.0
kVAh
kVArh
0.0
StatusScheduleI/OAlarmsEngine Generator
00405
07:10
kWh+
0.0
0.0
kVAh
kVArh
0.0
1/38
StatusScheduleI/OAlarmsEngine Generator
00406
Figure 3 - Input/Output Tab Screen
Schedule Tab
The Scheduler tab shows the current configuration and status of the scheduler, located below the generator summary. The maintenance configuration status and time remaining until an alarm, electrical trip or shutdown will be displayed at the bottom of the screen. The lamp(s) to the left shows the configuration status of the maintenance alarm, not the alarm condition.
33701 C MMG75D-100D Operating Manual 17
General Information
SITE GENSET 7741 \ 7740
Return Delay 10:00:00
0.0
kW
Scheduler Enabled to run Reserved Reserved
Event Week Day Start Stop Duration Event Week Day Start Stop Duration
GEN
V
-
+
All Monday 00:00 00:00 0:00
1
All Monday 00:00 00:00 0:00
2
All Monday 00:00 00:00 0:00
3 4
All Monday 00:00 00:00 0:00 All Monday 00:00 00:00 0:00
5
All Monday 00:00 00:00 0:00
6
All Monday 00:00 00:00 0:00
7
All Monday 00:00 00:00 0:00
8
Maintenance
1 250:00
2 500:00 3 3000:00
1/1
kVAr
250 hr Maint. - Refer to Manual
500 hr Maint. - Refer to Manual
3000 hr Maint. - Refer to Manual
AlarmsEngine Generator
480V/277V 3-Phase
Total Generator
0.0
kW
Hz
9 10 11 12 13 14 15 16
I/O
0.0
kVA
0.0
kVAr
%
0.0
0.00
pf
%
0.0
All Monday 00:00 00:00 0:00 All Monday 00:00 00:00 0:00 All Monday 00:00 00:00 0:00 All Monday 00:00 00:00 0:00 All Monday 00:00 00:00 0:00 All Monday 00:00 00:00 0:00 All Monday 00:00 00:00 0:00 All Monday 00:00 00:00 0:00
StatusSchedule
07:10
kWh+
0.0
kVAh
0.0
kVArh
0.0
ActionDescriptionAlarm Hours Date Time
Warning Warning Warning
00407
Figure 4 - Schedule Tab Screen
Status Tab
The Status tab contains the status and configuration of the controller, firmware and data connections.
SITE GENSET 7741 \ 7740
Return Delay 10:00:00
0.0 Hz
kW
kVAr
100%
Model Application USB ID Supervisor State: Engine State: Load State:
Protections: Logging Log Dest: Log Mode: USB drive: Host IP: Host Port:
GEN
V
-
+
- CTS
- RTS
- DTR
- DSR
- DCD
1/1
Model Application USB ID Bootloader Ethernet
Link Quality
480V/277V 3-Phase
%
0.0
%
0.0
Total Generator
kW
0.0
0.0
0.0
0.00
Bootloader Analogue Engine:
Tot al mem Log mem free Log Time:
Slave IP: Slave Port:
0.0
kVA
0.0
kVAr
pf
0.0
StatusScheduleI/OAlarmsEngine Generator
07:10
kWh+
kVAh
kVArh
00408
Figure 5 - Status Tab Screen

Generator Monitoring

Generator information is displayed on both the Generator button screen and Generator tab within the maintenance screens. For more information, refer to Generator Button and Generator Tab.

Engine Monitoring

Engine information is displayed on both the Engine operator screen and Engine tab within the maintenance screens. For more information, refer to Engine Button and Engine Tab.

Diesel Exhaust Filter Monitoring

This unit is equipped with a Diesel Particulate Filter (DPF) to meet current EPA emissions standards. This section gives an explanation of the indicators that are displayed on the DPF Status page of the Engine tab.
To access the DPF Status page, press any direction arrow (, , , ) to enter the maintenance screens, and then while on the Engine tab, press the button to toggle through the pages until the DPF Status page appears. There are four areas on the DPF Status page that communicate various information to the operator. The areas and the indicators that appear in those areas are explained here:
18 MMG75D-100D Operating Manual 33701 C
General Information
HEST Lamp (High Exhaust System Temperature): This area will display the Regeneration Underway indicator above the words “HEST Lamp - Solid” when the unit is in the process of diesel exhaust filter regeneration. During the regeneration process, the exhaust temperature will be very high.
DPF Status
HEST Lamp - Solid DPF Lamp
6/6
DPF Inhib Alarm
Engine
Generator
Alarms I/O Schedule Status
00409
Figure 6 - Regeneration Underway Indicator
DPF Lamp: This area will display the Regeneration indicator above the words “DPF Lamp - Solid” when auto exhaust filter cleaning is enabled. When the unit is being operated with auto exhaust filter cleaning disabled, the indicator will begin to flash above the words “DPF Lamp -Flashing” if the soot load level goes above 80%.
DPF Status
6/6
HEST Lamp DPF Lamp - Solid
DPF Inhib Alarm
Engine
Generator
Alarms I/O Schedule Status
DPF Status
6/6
HEST Lamp DPF Lamp - Flashing
DPF Inhib Alarm
Engine
Generator
Alarms I/O Schedule Status
00410
Figure 7 - Regeneration Indicator
DPF Inhib: This area will display the Disabled Regeneration indicator above the words “DPF Inhib - Solid” when auto exhaust filter cleaning is disabled.
DPF Status
HEST Lamp DPF Lamp
DPF Inhib - Solid Alarm
6/6
Engine
Generator
Alarms I/O Schedule Status
00411
Figure 8 - Disabled Regeneration Indicator
Alarm: This area will display the Engine Alarm indicator above the words “Alarm - Solid” when an alarm condition occurs. This area displays different text depending upon which alarm condition occurs.
DPF Status
HEST Lamp DPF Lamp
6/6
DPF Inhib Alarm - Solid
Engine
Generator
Alarms I/O Schedule Status
00412
Figure 9 - Engine Alarm Indicator
For more information on the operation of auto exhaust filter regeneration and service regeneration, see Exhaust
Filter Cleaning Operations.

Controller Information Displays, Functions, and Reset

The Power Zone™ controller constantly monitors vital generator and engine functions for a number of operation, alarm and fault conditions. When a fault condition occurs, the engine will shut down automatically and the main display will show the fault that has caused the shutdown. To resume operation, the fault condition must be resolved.
33701 C MMG75D-100D Operating Manual 19
General Information
To reset the controller and resume operation, press the Enter () button.

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.

FRONT HOOD OPERATION

Figure A
01891
Figure 10 - Front Hood Operation
WARNING
Stay clear of hood and lift structure when opening and closing generator hoods.
Personal injury could result.

To Open the Front Hood

1. With your right hand, grip the handle located on the front panel.
2. With your left hand, pull the hood latch located on the upper corner of the hood. See Figure A. Tilt the hood open until it contacts the bulkhead panel.
CAUTION
Generator hoods are heavy. Use caution when opening or closing.
20 MMG75D-100D Operating Manual 33701 C

To Close the Front Hood

1. Make sure the skid is free of debris and all personnel are clear of unit.
CAUTION
Do not attempt to close the hood from the sides of the unit. Failure to close the hood correctly
could result in personal injury and equipment damage.
2. While standing at the front of the unit, slowly push the hood forward until firmly closed.
3. Verify the hood is securely closed by attempting to open without pulling the hood latch.
General Information
33701 C MMG75D-100D Operating Manual 21
General Information
This Page Intentionally Left Blank
22 MMG75D-100D Operating Manual 33701 C
Section 3 - Operation

PRESTART CHECKLIST

Before starting the unit, all items in the prestart checklist must be completed. This checklist applies to both manual and remote starting of the unit.
Read and understand ALL safety sections at the beginning of this manual.Verify all maintenance procedures are up to date. For more information, see General Maintenance
and Basic Maintenance Schedule.
The unit must be level.The unit must be dry. Verify there is no water inside, on, or near the unit; dry if needed.For grounding requirements, follow any local, state, or National Electrical Code (NEC) guidelines.Verify the Control Power switch is OFF (O).Verify all circuit breakers are OFF (O).Inspect all electrical cords; repair or replace any that are cut, worn, or bare.Verify oil, coolant, and fuel levels are correct, per the engine manufacturer manual.Verify battery connections are secure.Turn the battery disconnect switch on, if equipped.Check the engine fan belt tension and condition.Check the engine fan belt guard.Check the engine exhaust system for loose or rusted components.Verify all covers are in place and secure.Verify all electrical connections at the connection lugs, if equipped, are tight and wired correctly.Verify the voltage selector switch is set to the desired voltage and locked.Verify the emergency stop switch is pulled out.Verify the radiator and surrounding shroud are clear of debris.

MANUALLY STARTING 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 ON (I).
DANGER
CARBON MONOXIDE: USING A GENERATOR INDOORS CAN KILL YOU IN MINUTES.
2. The LCD window will show the prestart diagnosis and the controller will load the unit management software.
TM
Image File Transer...
82%
00414
Figure 3-1. Prestart Screen
33701 C MMG75D-100D Operating Manual 23
Operation
3. When the software is loaded, the Home screen will be displayed and the controller will be in Stop mode as
indicated at the top of the screen. Press the Auto/Manual Mode ( ) button to enter Manual mode.
Stop Mode
Time to Empty
15 hr
110
100
0.0 kW
GEN
V
-
+
10
60
50
40
30
20
0
90
80
70
%
3 PHASE
Volts
0
Amps
0
Figure 3-2. Home Screen
Note: The controller can be started from any screen when it is in Manual mode.
4. Pressing the green Engine Start (I) button on the controller will initiate the startup procedure and start the
engine, provided there are no engine faults preventing the unit from starting.
Full
3/4
1/2
1/4
Empty
74
%
00415
Note: It may take a few seconds for the engine to run smoothly and reach its governed operating speed. During this time, the screen will show a voltage different from that set with the voltage selector switch.
5. If the engine does not start after the first cranking attempt, the engine will pause for 15 seconds to allow the
starter to cool. The LCD window will show “Manual Mode - Crank Rest” at the top of the screen. The engine will make two more attempts to start for a total of three crank cycles.
6. Should the engine not start and run within three crank cycles, the LCD window will show the “Fail to Start”
alarm. The starting sequence may be repeated after the starter has had a minimum of two minutes to cool. Pressing the Enter () button will clear the alarm and reset the controller.
Note: The engine controller may skip the preheat engine steps on some of the larger models.
7. Once the engine starts, it will immediately begin speeding up to a constant 1800 rpm. The engine may hunt
or change speeds until operating speed is reached. After a few minutes of operation, the engine will be warmed up and the operator screens will show engine and generator operating parameters.
8. Check the generator for excessive noise or vibration and any coolant, oil, or fuel leaks before applying any
loads.
9. Check that the AC output voltage is correct. The output voltage can be fine adjusted by using the Voltage
Adjust screen as described on page 27.
10. Check that the frequency (Hz) is correct on the Generator screen. With no loads connected to the generator,
the frequency should read approximately 60 Hz, depending on the type of engine governing used.
11. If all wiring connections have been made correctly, switch the main circuit breaker to the ON (I) position and
then add any loads attached to the receptacles by switching the respective circuit breaker to the ON (I) posi­tion. You will notice a slight change in engine sound when a load is applied to the unit.

AUTO (REMOTE) STARTING THE UNIT

Auto mode is used when the unit is started from a location other than the control panel by using a transfer switch. Auto (remote start) is the normal setting when the unit is being used as a standby power supply. Before putting the unit in the Auto mode, review the Prestart Checklist and Manually Starting the Unit. Follow all safety warnings
24 MMG75D-100D Operating Manual 33701 C
Operation
and review all information on isolating the generator with a transfer switch if the unit is to be used as a standby power supply. See Auto Exercise Timer, then continue with the steps described below:
1. Perform a manual start of the unit at least once to verify that the engine is operating correctly.
2. If a check of the remote start circuit is desired, remove the wires from the remote start terminal block. Press
the Auto/Manual Mode ( ) button, the LCD window should show “Auto Mode” at the top of the screen. Attach a jumper wire (minimum 16 gauge) across the two terminals on the remote start terminal block. This applies a ground to the Power Zone™ Controller to close the starting circuit contacts. The engine should crank, start and run.
3. Remove the jumper wire from the remote start terminal block and the engine will stop. Reconnect any nec-
essary wires from the remote start switch (transfer switch) to the remote start terminal block.
4. Confirm the unit is in Auto mode. The LCD window should show “Auto Mode” at the top of the screen.
5. Close the main circuit breaker (set to ON (I)).
6. Secure the unit by closing and locking all access doors.
7. The unit is now ready for remote starting.
The remote start terminal block provides a connection for installation of a remote start switch which will allow the unit to be started by a remote dry-contact closure switch. For location of the remote start terminal block, see Control Panel.
Before entering Auto mode, verify that the contacts on any remote switch linked to the unit are OPEN. If the contacts on a remote switch are closed, the engine will crank and start when Auto mode is entered. Attach the switch leads to the two unused terminals on the unit’s remote start terminal block.
Remote Start
Switch Terminals
00231
Figure 3-3. Remote Start
Terminal Block

TRANSFER SWITCH

The generator neutral is bonded to ground when shipped from the factory. The bonding plate will need to be removed when the unit is used as a standby power supply. Installation should be in compliance with the National Electrical Code (NEC), state and local regulations.
When the unit is used as a standby power supply, it must be equipped with a transfer switch which isolates it from the utility’s distribution system. A transfer switch is designed to transfer electrical loads from the normal power source (utility) to the emergency power source (generator) when normal voltage falls below a prescribed level. The transfer switch automatically returns the load back to the normal source when power is restored back to operating levels.
33701 C MMG75D-100D Operating Manual 25
Operation
Incoming
Utility
Power
Utility
Meter
Power From
Generator
FAILURE TO ISOLATE THE GENERATOR FROM THE NORMAL POWER UTILITY CAN CAUSE POTENTIALLY LETHAL VOLTAGE TO BACKFEED INTO THE UTILITY LINES. THIS WILL 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
Emergency
Distribution Panel
(Generator Power)
Main
Distribution Panel
(Utility Power)
Transfer
Switch
Figure 3-4. Transfer Switch Operation
WHITE = Incoming Utility Power
GRAY = Normal Utility Power Circuit
BLACK = Emergency Generator Power Circuit
DANGER
AS A BACKUP TO SOME OTHER TYPE OF POWER SUPPLY.
00206
Installation of such devices must be performed by following all directions supplied by the manufacturer of the switch. If attaching the unit to a power supply normally serviced by a utility company, notify the utility company and check state and local regulations. Familiarize yourself with all instructions and warning labels supplied with the switch.
WARNING
ONLY a licensed electrician should perform wiring and related connections to the
generator. Installation should be in compliance with the National Electrical Code
(NEC), state and local regulations. Failure to follow these procedures could result in
property damage, personal injury or death. Before any connections are attempted, make sure the main circuit breaker and the Control Power switch are in the OFF (O) position and that the negative (-) battery cable has been disconnected from the battery.
When using the unit 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.

DERATING FOR ALTITUDE

All units are subject to derating for altitude; this will reduce the available power for operating tools and accessories connected to the receptacles. Typical reductions in performance are 5% above 10,000 ft (3048 m) of elevation.
26 MMG75D-100D Operating Manual 33701 C
Operation

GENERATOR OUTPUT CONNECTIONS

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
Only a trained and licensed electrician should perform wiring and connections to
unit. Failure to follow proper installation requirements could result in death, serious
injury, and damage to equipment or property. (000155)
WARNING
Before any connections are made to the generator, make sure that the main circuit breaker and the Control Power switch are OFF (O). Potentially lethal voltages may be
present at the generator connection lugs.
DANGER
IMPROPER OR INCORRECT CONNECTIONS TO A BUILDING’S ELECTRICAL SYSTEM CAN CAUSE POTENTIALLY LETHAL VOLTAGES TO BACKFEED INTO UTILITY LINES. THIS MAY RESULT IN INJURY OR ELECTROCUTION TO UTILITY WORKERS NEARBY.
MAKE SURE THE GENERATOR IS SUPPLYING POWER TO AN ISOLATED OBJECT
OR BUILDING THAT IS NOT CONNECTED TO ANY UTILITY LINES.
Connections to the lugs should be made by running the power cables up through the opening in the bottom of the box. DO NOT make any connections directly to the lugs without routing the cables through the opening. Use a hex­wrench 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
switch(es). Equipment
damage, personal injury or
death could result.
Run Cables Through Slots
Figure 3-5. Generator Connection Lugs
A ground connection is located next to the connection lugs. The unit MUST be connected to ground for proper operating safety. The generator neutral is bonded to ground when it is shipped from the factory. The bonding plate will need to be removed when the generator is used as a standby power source. INSTALLATION SHOULD BE IN
COMPLIANCE WITH THE NATIONAL ELECTRICAL CODE (NEC), STATE AND LOCAL REGULATIONS.
01892

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.
33701 C MMG75D-100D Operating Manual 27
Operation
V
V
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
L-N Average
277
L-L Average
00396
Figure 3-6. Voltage Adjust Screen
V
1. With the unit running, press .
2. Press . The voltages displayed will begin flashing.
3. Use and to adjust the voltage.
4. Press to confirm the new voltage. The voltages displayed will stop flashing.
-
+

VOLTAGE SELECTOR SWITCH

The voltage selector switch mechanically changes the connections between the generator output leads and the connection lugs on the main control panel. Voltage ranges are selected by rotating the handle on the switch to the desired voltage.
WARNING
Electric Shock. Never change the voltage selector switch while the engine is running
or the controller is on. If the engine is running or starts while the setting is being
changed, severe arcing will occur, resulting in death, serious injury or damage to the
switch and generator windings.
The voltage selector switch is equipped with a lockout mechanism. Once the proper voltage has been selected, insert a padlock through the lockout hole(s). By locking the handle in place, unauthorized changing of the voltage setting is prevented.
120/208V 3-PHASE
120/ 208V
L1-L2 = 208V L1-N = 120V N = L2-L3 = 208V L2-N = 120V L3-L1 = 208V L3-N = 120V
277/ 480V
120/ 240V
VOLTAGES AT RECEPTACLES
RECEPTACLE L-L L-N
GFCI - 120V GFCI w/Buck - 120V
Switch styles vary by model.
28 MMG75D-100D Operating Manual 33701 C
Twist-locks 208V 120V
00085
120/ 208V
277/ 480V
Switch styles vary by model.
= Not recommended for normal use
120/ 208V
277/ 480V
Switch styles vary by model.
= Not recommended for normal use
120/ 240V 3PH
120/ 240V 1PH
Operation
277/480V 3-PHASE
L1-L2 = 480V L1-N = 277V N = L2-L3 = 480V L2-N = 277V L3-L1 = 480V L3-N = 277V
VOLTAGES AT RECEPTACLES
RECEPTACLE L-L L-N
GFCI - 139V GFCI w/Buck - 120V Twist-locks 240V 139V
00083
120/240V 3-PHASE
L1-L2 = 240V L1-N = 120V N = L2-L3 = 240V L2-N = 208V L3-L1 = 240V L3-N = 120V
VOLTAGES AT RECEPTACLES
RECEPTACLE L-L L-N
GFCI - 120V GFCI w/Buck - 120V Twist-locks 120V 0/120V
4 Position Voltage Selector Switch Option
00086
120/240V 1-PHASE
120/ 208V
L1-L2 = - L1-N = 120V N = L2-L3 = - L2-N = ­L3-L1 = 240V L3-N = 120V
120/ 240V
VOLTAGES AT RECEPTACLES
RECEPTACLE L-L L-N
GFCI - 120V GFCI w/Buck - 120V
Switch styles vary by model.
Twist-locks 240V 120V
00087
Figure 3-7. Voltage Selector Switch Settings

VOLTAGE REGULATOR

The automatic voltage regulator controls the output of the generator by regulating the current into the exciter field. The regulator has four screwdriver adjustable potentiometers that may be adjusted for under frequency (U/F) dip, protention (U/F), stability, and voltage. The voltage regulator is adjusted before shipment from the factory. Contact Generac Mobile Products LLC for additional information before attempting to adjust the voltage regulator.
Note: For units equipped with a Marathon DVR2000E+ automatic voltage regulator, see the Marathon operating manual provided with the unit.
33701 C MMG75D-100D Operating Manual 29
Operation

CUSTOMER CONVENIENCE RECEPTACLES

The unit is equipped with five receptacles. The 240/ 120VAC twist-lock receptacles are rated at 50A each. The 120VAC duplex receptacles are rated at 20A each, with ground fault circuit interrupt (GFCI) protec­tion. The receptacles are not routed through the main circuit breaker. Each receptacle has its own circuit breaker, located directly above or next to the recep­tacle. Each breaker is sized to the maximum rating of the corresponding receptacle.
Power to the receptacles is
available any time the generator
is running, even if the main circuit
breaker is OFF (O). Verify
equipment connected to the
receptacles is turned off before
turning the breakers on. Verify the
voltage selector switch is in the
proper position and that the
output voltage is correct for the
equipment connected to the
receptacles. Improper voltage
may cause equipment damage or
malfunction.
20A Circuit
Breakers
50A Circuit
Breakers
120V GFCI
Receptacles
120/240V
Twist-Lock
Receptacles
Figure 3-8. Receptacle and Breaker Locations
00453
Note: When the voltage selector switch is in position for 480/277V 3Ø, voltage at the two GFCI receptacles is 139 volts and the voltage at the three twist-lock receptacles is 240/139 volts. Generac Mobile Products LLC does not recommend using the receptacles in the 480V position. When the voltage selector switch is in position for 208/120V 3Ø, voltage at the three twist-lock receptacles and the two GFCI receptacles is 208/120 volts.

MAIN CIRCUIT BREAKER

The main circuit breaker is located on the main control panel (see Figure 2-4). When the breaker is OFF (O), power is interrupted to the connection lugs, the optional cam lock receptacles, and the generator. Once the connections have been made to the connection lugs or the optional cam lock receptacles, and the unit has been started and allowed to reach normal operating temperature, the breaker may be switched ON (I).
The main circuit breaker will be tripped, disconnecting power to the connection lugs and the optional cam lock receptacles if any of the following items occur while the unit is running:
1. Overload of the generator circuits to the connection lugs or the optional cam lock receptacles.
2. The door covering the connection lugs or the optional cam lock receptacles is opened.
On/I
Off/O
On/I
Off/O
00452
Figure 3-9. Main Circuit
Breaker
3. If the emergency stop switch is activated.
30 MMG75D-100D Operating Manual 33701 C
Operation
Make sure any problems that cause the main circuit breaker to trip are corrected before returning the switch to ON (I).
The main circuit breaker interrupts power to the connection lugs and the optional cam lock receptacles only. The customer convenience receptacles have power even if the main circuit
breaker is OFF (O). To disconnect power to these receptacles, use the individual circuit
breakers located near each receptacle.

EXHAUST FILTER CLEANING OPERATIONS

When enabled, the exhaust filter system goes through an automatic cleaning process known as regeneration. Under normal circumstances, regeneration occurs without interruption of unit operation and with minimal operator involve­ment. In the event there are conditions requiring the operation of the unit with the auto exhaust filter cleaning disabled, the operator may be required to perform procedures to enable or disable the auto exhaust filter cleaning. The operator may also be required to perform a manual regeneration.
WARNING
The area above and surrounding the exhaust system during an auto or manual exhaust filter cleaning should be clear of people and objects. Exhaust gases and components
can reach temperatures hot enough to ignite and melt common materials.
Note: Always park the unit in a safe location for elevated exhaust temperatures and check for adequate fuel level before beginning the exhaust filter cleaning process. The cleaning cycle can take an extended period of time (approximately 45 minutes). Cleaning is complete when the Regeneration indicator remains off.

Disabling Automatic (Auto) Exhaust Filter Cleaning

The auto exhaust filter cleaning feature should always be enabled unless doing so would cause an unsafe working environment. In the event that an unsafe working environment would occur, use the following procedure to disable the auto exhaust filter cleaning feature:
1. Open the control door and locate the switch labeled “EXHAUST FILTER CLEANING.”
2. Move the switch to DISABLED (O).
3. Enter the DPF Status screen and verify the Disabled Regeneration indicator appears above the words “DPF
Inhib - Solid.” For information regarding the DPF Status screen and indicators, see Diesel Exhaust Filter
Monitoring.
Disabling Auto Exhaust Filter Cleaning is not recommended for any situation unless it is
safety related or if the fuel tank lacks the required fuel to complete the cleaning process.

Force a Manual Exhaust Filter Cleaning

If running the unit with the exhaust filter cleaning function disabled, the DPF Status screen may display a red alarm, prompting the operator to force a manual exhaust filter cleaning. Use the following procedure to force a manual exhaust filter cleaning feature:
1. Open the control door and locate the switch labeled “EXHAUST FILTER CLEANING.”
2. Move and hold the switch in ON/FORCED (I) for five seconds.
33701 C MMG75D-100D Operating Manual 31
Operation
3. Enter the DPF Status screen and verify the Regeneration indicator appears above the words “DPF Lamp -
Solid.” For information regarding the DPF Status screen and indicators, see Diesel Exhaust Filter Moni-
toring.

Enable Exhaust Filter Cleaning

If the environment no longer requires the function to be disabled and there are no alarms present on the DPF Status screen, the auto exhaust filter cleaning function should be enabled. Use the following procedure to enable the auto exhaust filter cleaning feature:
1. Open the control door and locate the switch labeled “EXHAUST FILTER CLEANING.”
2. Move the switch to ON/AUTO (I/O).
3. Enter the DPF Status screen and verify the Regeneration indicator appears above the words “DPF Lamp -
Solid.” For information regarding the DPF Status screen and indicators, see Diesel Exhaust Filter Moni-
toring.

AUTO EXERCISE TIMER

The Power Zone™ controller is capable of starting and stopping the unit automatically, based on a programmable schedule.
Units installed in a standby application should be exercised regularly to maintain operating condition and to ensure responsiveness in an emergency situation. Use the following procedures to operate the unit in Auto mode:

Accessing the Configuration Menu

1. With the unit stopped, press ▲, ►, ▼, or ◄ to navigate to the maintenance screens from any of the operator screens.
2. While on any maintenance screen, press and O simultaneously. The controller will display the Configura-
tion menu.
3. To save any changes and exit the Configuration menu, press and hold for five seconds. To cancel any
changes and return to the maintenance screen, press and hold O for five seconds.

Set the Controller Clock

The schedule runs based off the time set in the controller clock. Use the following procedure to set the controller clock BEFORE setting the schedule:
1. Navigate to the Maintenance group and press to access it.
2. Press to select the Time section.
3. Set the time and date to the correct local time.

Set the Schedule

Note: The controller must be in Auto mode to run at the programmed time. Use a trickle or solar battery charger to prevent the controller from draining the battery while in Auto mode.
32 MMG75D-100D Operating Manual 33701 C
Operation
1. Access the Scheduler group by pressing the button.
Note: The Scheduler group is made up of the Scheduler Options and Scheduler Setup sections. Each section can be accessed and exited using the and buttons.
2. Access the Scheduler Options section. Within this section, the scheduler can be enabled, run mode
selected, and load mode selected.
Table 2: Scheduler Options
Item Values
Enable Yes/No
Run Mode Monthly/Weekly
Load Idle, In Island, On Load, Off Load
3. Access the Scheduler Setup section. Within this section, each schedule entry can be modified by pressing
the button to select the item and the and buttons to define them.
Table 3: Scheduler Setup
Item Values
Schedule Entry 1-16
Start Time 00:00-23:59
Duration 00:00-99:59
Day Monday-Sunday
Week (of month) First, Second, Third, Fourth
Note: If setting up a daily scheduled run, select Weekly run mode, then set Start Time and Duration for each day (seven schedule entries total). This will repeat the seven day schedule as long as the unit is in Auto mode.

Set the Unit to Auto Mode

1. From any operator or maintenance screen, press and hold the Auto/Manual Mode ( ) button for five seconds, or until Auto mode is displayed at the top of the screen.
Note: If any of the scheduled time slots are currently active, the controller will begin the starting sequence and start the unit, provided there are no shutdown conditions present.

SHUTTING DOWN THE UNIT

Prior to shutting down the unit, check with personnel using power supplied by the generator and let them know that the power is going to be turned off. Verify the power shut down will not create any hazards by accidentally turning off equipment that needs to be kept on (pumps, compressors, lights, etc.).
1. Remove all loads from the generator by opening all circuit breakers (turn OFF (O)).
2. Let the engine run for approximately five minutes to allow it to cool down.
3. Press the red Engine Stop/Reset (O) button on the controller. This will result in the generator going into the
shutdown cycle and starting a 15 second shutdown timer called stopping. If the unit does not shut down within 15 seconds, a stop fail alarm will be displayed on the LCD window.
33701 C MMG75D-100D Operating Manual 33
Operation
4. After the unit shuts down, move the Control Power switch to OFF (O).
Note: For extended storage time, disconnect the battery. See the engine operator’s manual for extended storage requirements.

EMERGENCY STOP SWITCH

The unit is equipped with one emergency stop switch. For location of the emergency stop switch, see Component Locations. The red button is clearly labeled “EMER-
G
E
GENCY STOP.” The switch can be accessed and activated with all doors closed and locked.
Activate the emergency stop switch by pushing the button in until it locks down. This will trip the main circuit breaker which will open the contact, disconnecting the load to the connection lugs. This will also open the fuel circuit, shutting down the engine. The emergency stop fault will be displayed on the control panel. The switch will remain closed until it is pulled out.
Figure 3-10. Emergency
Equipment Damage. The emergency stop switch is not to be used to power down the unit under normal operating circumstances. Doing so will result in equipment damage. (000246)
R
N
E
M
E
C
Y
S
T
P
O
Stop Switch
00230

ECU OVERRIDE SWITCH

The ECU override switch is located inside the control box. This toggle switch powers up the ECU without having to start the engine. Use the ECU override switch to turn the ECU off. If the unit needs to be shut down immediately, use the emergency stop switch. See Emergency Stop Switch for additional information.
DO NOT start the engine with the ECU override switch on. Doing so will
damage the ECU.
00420
Figure 3-11. ECU Override
Switch

TOWING THE UNIT

Once the engine is shut down, follow these steps to prepare the unit for towing.
1. Use the tongue jack to raise or lower the trailer onto the hitch of the towing vehicle. Lock the hitch coupling and attach the safety chains or cables to the vehicle. Release the jack locking pin and rotate the jack into the travel position. Make sure the locking pin snaps into place.
Note: 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 unit is towed.
2. To ensure proper operation of the jacks, lube the grease fittings located on the leveling jacks. See Jack
Maintenance. For maintenance interval information, see Basic Maintenance Schedule.
3. Connect trailer wiring to the tow vehicle. Check for proper operation of the directional and brake lights.
34 MMG75D-100D Operating Manual 33701 C
4. Verify all doors and hoods are properly latched.
5. Check for proper inflation of the trailer tires. For maximum tire pressures, see Specifications.
6. Check the wheel lugs. Tighten or replace any lugs 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:
Operation
a. Start all lug nuts by hand.
b. First pass tighten to 20-25 ft-lbs (27-33 Nm).
3
1
5
6
2
4
c. Second pass tighten to 50-60 ft-lbs (67-81 Nm).
d. Third pass tighten to 90-120 ft-lbs (122-162 Nm).
Note: After first road use, repeat tightening procedure.
Figure 3-12. Lug
Sequence
7. Maximum recommended speed for highway towing is 45 mph (72 km/h). Recommended off-road towing
speed is 10 mph (16 km/h) or less, depending on the terrain.

LIFTING THE UNIT

A central lift point is located on the top of the unit. The
Central
Lift Point
central lift point is connected to a lift structure inside the unit. Attach a sling or hook directly to the central lift point only if the devices are in good condition and the equip­ment being used to raise the unit has sufficient capacity. For approximate weights, see Specifications. Always remain aware of people and objects around when moving or lifting the unit. Keep the doors and hood closed and locked.
00205
02071
Figure 3-13. Central Lift Point Location
33701 C MMG75D-100D Operating Manual 35
Operation
This Page Intentionally Left Blank
36 MMG75D-100D Operating Manual 33701 C
Section 4 - Maintenance

EMISSIONS INFORMATION

For emissions information, see the OEM engine manual.

DAILY WALK AROUND INSPECTION

Look for conditions that could hinder performance or safety, such as (but not limited to) oil/coolant/fuel leakage, blocked vents, loose/missing hardware, and electrical connections.
Visually inspect the fan belt for cracks, fraying, stretching, and verify the belt is properly seated in the pulley grooves. Replace the belt according to the manufacturer’s recommendations.
Note: At the 500 hour/12 month service interval, it is recommended that the belt be removed and checked for wear. While the belt is removed, inspect pulleys and bearings. Rotate and feel for hard turning or unusual sounds. If pulleys or bearings need replacement, contact the engine manufacturer.
Failure to perform a daily inspection could result in serious damage to the prime mover.

GENERAL MAINTENANCE

Poorly maintained equipment can become a safety hazard. In order for the equipment to operate safely and properly over a long period of time, periodic maintenance and occasional repairs are necessary. NEVER perform routine service (oil/filter changes, cleaning, etc.) unless all electrical components are shut off. Before servicing the unit, always follow the instructions listed below.
Verify the Control Power switch is turned OFF (O).
Verify the circuit breakers are turned OFF (O).
Activate (push in) the emergency stop switch.
Disconnect the negative (-) terminal on the battery.
Attach a “Do Not Start” sign to the control panel. This will notify everyone that the unit is being serviced and will reduce the chance of someone inadvertently trying to start the unit.
Do not wash the unit with a high pressure hose or with any kind of power washer.
Do not 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.
Verify the condition of the air filter by viewing the level of the vacuum draw on the filter minder gauge. Replace the air filter when the yellow center bar reaches the red section on the gauge (20 in. H2O).
Check wheel lugs. see Towing the Unit.
Check coolant level daily. See the engine operator’s manual for coolant recommendations and proper mixture.
Coolant is checked visually by inspecting the level in the coolant overflow jug located near the radiator. Normal operating level is between the FULL and ADD markings on the overflow jug, also known as the
normal range.
When engine is stopped and completely cool, coolant may be added directly to the coolant overflow jug.
33701 C MMG75D-100D Operating Manual 37
Maintenance
Verify the oil level daily. See the engine operator’s manual for the proper viscosity grade of oil, including special operating conditions such as a change in season or climate.
DO NOT start the unit if the engine oil level is below the add mark on the dipstick. Normal operating level is in the cross-hatch pattern between the FULL and ADD markings on the dipstick. Add oil only if the oil level is below the ADD mark on the bottom of the cross-hatch pattern on the dipstick. DO NOT OVERFILL the crankcase.
Verify the fuel level.
If the unit is connected to a remote start or transfer switch, make sure the remote switch is also off and tagged.
Note: If the engine was run out of fuel or the fuel tank was drained, it may be necessary to bleed the fuel lines. See the engine operator’s manual supplied with the unit for more information.

BASIC MAINTENANCE SCHEDULE

See the original equipment manufacturer’s operating manual for a complete list of mainte-
nance requirements. Failure to comply with the procedures as described in the engine operator manual will nullify the warranty, decrease performance and cause equipment
damage or premature equipment failure. Maintenance records may be required to complete
a warranty request.
Use the schedule in the following table as a guide for regular maintenance intervals.
Table 4: Basic Maintenance Schedule
100
Hrs.
Item Daily
Check Oil Level Check Coolant Level Check Fuel Level Check Tire Pressure Check All Electrical Connections Inspect Radiator Fins For Debris, Clean As
Required Check Fuel Filter/Water Separator Bowl Check Air Cleaner Filter Minder Gauge * Perform Visual Walkaround Inspection Check Oil Vapor Recirculation System/Non-
Return Valve Change Engine Oil and Replace Oil Filter ** Replace Oil Vapor Recirculation Filter Service Battery Replace Fuel Filter Elements Check Engine Mounts Check Air Intake Hoses, Connections, and
System Check Engine Electrical Ground Connection
(Break-
In
Period
Only)
Every
250
Hrs.
Every
500
Hrs./12
Month
s
Every
1000
Hrs.
Every
3000
Hrs./36
Months
As
Require
d
38 MMG75D-100D Operating Manual 33701 C
Table 4: Basic Maintenance Schedule
Maintenance
100
Hrs.
Item Daily
Check Automatic Belt Tensioner and Belt Wear
Check Cooling System Lubricate Leveling Jack(s) Check Generator Drive Plate Torque (see
Checking Generator Drive Plate Torque)
Replace OVR filter Replace oil filter Replace air filter Replace primary fuel filter Replace fuel filter final Replace fan belt Test Thermostats Replace Air Cleaner Elements Replace Alternator and Fan Belts Check Fuses
(Break-
In
Period
Only)
Every
250
Hrs.
Every
500
Hrs./12
Month
s
Every
1000
Hrs.
Every
3000
Hrs./36
Months
As
Require
d
* Replace primary air cleaner when filter minder gauge shows a vacuum of 25 in. H2O. ** If not using John Deere Plus 50 II engine oil, the interval must be decreased to every 250 hours.

ENGINE BREAK-IN REQUIREMENTS

Note: During the first 20 hours of operation, avoid long periods of no load or sustained maximum load operation. If the generator is to run for longer than five minutes without a load, shut the generator down.
John Deere engines are supplied with engine break-in oil from the factory. Extra care during the first 100 hours of engine operation will result in better performance and longer engine life. DO NOT exceed 100 hours of operation with the break-in oil. Operate the engine at heavy loads (60-90% of maximum) as much as possible. If the engine has spent significant time at idle, constant speed(s), and/or light load, or if makeup oil is required, a longer break in period may be needed. See the engine operator’s manual for a full description of necessary procedures on the addition of break-in oil and extension of the break-in period.

RESETTING THE MAINTENANCE ALARMS

The Power Zone™ controller will display a warning message when the unit is due for maintenance or service. The maintenance or service interval is set at 250, 500 and 3000 hours of engine running time. Once the unit has been serviced, the appropriate maintenance alarm reminder needs to be reset. The following procedure demonstrates how to reset the maintenance alarms:
1. With the unit shut down, move the Control Power switch to “CONTROL ON (/I)”. After initialization, the controller will toggle automatically to the Home screen.
2. Press , , , or to enter the maintenance screens.
3. Press and O simultaneously. The next screen will display the Configuration menu.
33701 C MMG75D-100D Operating Manual 39
Maintenance
4. Press to move the cursor (blue highlighted text) down to the Maintenance group.
5. Press to access the sections. Press to highlight the Maintenance section.
6. Press to access the parameters and highlight the maintenance alarm that needs to be reset.
7. Press to select the editable parameters. The cursor will highlight “Not Reset” under the selected mainte-
nance alarm. Press to highlight “Reset”.
8. Press to reset the selected maintenance alarm.
9. To perform additional maintenance alarm resets, repeat steps 6 - 8.
Note: If the selected maintenance alarm does not need to be reset, press to highlight “Not Reset” and press to return to the parameters section.
10. To save changes, press and hold for five seconds. To discard changes made, press and hold O for five
seconds.

EXHAUST FILTER SERVICE REQUIREMENTS

The exhaust filter system contains a Diesel Particulate Filter (DPF). Over time, the DPF will require professional servicing to remove ash buildup. The expected service interval will be at least 3,000 or 4,500 hours, based on engine power and operating conditions. Actual service should take place when the indicator light appears on the Power Zone™ controller. The DPF should be cleaned or replaced by an OEM authorized engine service dealer only. The removal of DPF ash must be done by removing the DPF from the unit and placing it into specialized equipment.
CAUTION
Do not remove ash by using water or other chemicals. Removing ash by these methods
may cause equipment damage and create unsafe operating conditions.
CAUTION
Only a OEM authorized engine service dealer should remove, handle and dispose of DPF ash. These materials may be considered hazardous under federal, state and local regula-
tions, and must be handled and disposed of properly.
To avoid unnecessary buildup of diesel particulates or soot in the exhaust filter system:
1. Utilize the Automatic Exhaust Filter Cleaning mode.
2. Avoid unnecessary idling.
3. Use proper engine oil. See the engine operator’s manual.
4. Use only ultra low sulfur diesel fuel. See the engine operator’s manual.

CHECKING GENERATOR DRIVE PLATE TORQUE

Follow the procedure below to check the torque of the generator drive plate bolts in accordance with the maintenance chart.
1. Disconnect battery.
2. Remove generator fan guard.
40 MMG75D-100D Operating Manual 33701 C
Maintenance
3. Torque each of the drive plate bolts to the appropriate specification shown in the table below.
Table 5: Drive Plate Bolt Torques
Unit ft-lbs (Nm)
MMG75D 36 (49) MMG100D 36 (49)
4. Install generator fan guard.
5. Connect battery.

JACK MAINTENANCE

The following procedures should be performed annually.

Side-Wind Models

The internal gearing and bushings of the jack must be kept lubricated. Apply a small amount of automotive grease to the internal gearing by removing the jack cover, or if equipped, use a needle nose applicator or standard grease gun on the lubrication point found on the side of the jack near the crank. Rotate the jack handle to distribute the grease evenly.
A lightweight oil must be applied to the handle unit at both sides of the tube.
If equipped, the axle bolt and nut assembly of the caster wheel must also be lubricated with the same lightweight oil.

Top-Wind Models

Apply a lightweight oil to the screw stem.
Oil
Grease
Grease
Oil
Grease
Oil
Oil
Oil
00243
Figure 4-14. Lubrication Points

TRAILER WHEEL BEARINGS

The trailer axles are equipped with a grease fitting to allow lubrication of the wheel bearings without the need to disassemble the axle hub. To lubricate the axle bearings, remove the small rubber plug on the grease cap, attach a standard grease gun fitting to the grease fitting and pump grease into the fitting until new grease is visible around the nozzle of the grease gun. Use only a high quality grease made specifically for lubrication of wheel bearings. Wipe any excess grease from the hub with a clean cloth and replace the rubber plug when finished. The minimum recommended lubrication is every 12 months or 12,000 miles (19,312 km). More frequent lubrication may be required under extremely dusty or damp operating conditions.
33701 C MMG75D-100D Operating Manual 41
Maintenance
This Page Intentionally Left Blank
42 MMG75D-100D Operating Manual 33701 C
Section 5 - Troubleshooting

GENERAL TROUBLESHOOTING

This information is intended to be a check or verification for simple causes that can be located and fixed. It does not cover all types of problems. See the engine operator’s manual for additional troubleshooting information. Procedures that require in-depth knowledge or skills should be referred to a trained technician.
Table 6 - General Troubleshooting Guide
Problem
Low Fuel Level Shutdown
Low Oil Pressure Shutdown
Low Coolant Level Shutdown
Cause Solution
Low fuel level
Unit not level
Fuel tank leaking
Damaged fuel sender or wiring
Low oil level
Oil leaking from engine
Oil pressure sender
Low coolant level
Coolant hoses leaking
Engine block or water pump leaking
Check fuel level in LCD window of controller.
Confirm that unit is sitting level to ensure an accurate reading.
Check tank for leaks.
Check for continuity between sender and engine controller. (See
DC Wiring.)
Check oil level on dipstick. Add oil, if needed.
Visually inspect the engine for leaks. Restart unit and verify loss of pressure. Shut down immediately if pressure does not reach 5 psi (34 kPa) within five seconds.
See engine operator’s manual to identify corrective action.
Allow engine to cool, then check coolant level in radiator. Add coolant, if needed.
Inspect hoses for leaks. Repair or replace as necessary.
Visually inspect for leaks. Verify no coolant has mixed with the engine oil (oil will appear milky). See engine operator’s manual for additional information.
Add coolant if needed. Allow engine to cool, then check coolant
Low coolant level
High Coolant Temperature Shutdown
Overcrank Shutdown Fuel level low
Overspeed or Underspeed Shutdown
33701 C MMG75D-100D Operating Manual 43
Blockage in radiator
Leakage in coolant hoses, engine block, or water pump
Frequency setting incorrect
level in radiator. Restart engine and check coolant temperature (on controller). Stop engine immediately if coolant temperature is 210°F (99°C) or more.
Check radiator shroud and ducting for blockage and remove any foreign matter.
Inspect for visible leaks. Check tension of water pump serpentine drive belt. Remove load on generator and restart engine. Check coolant temperature and shut engine down immediately if it starts to over­heat (230 degrees or higher). See the engine operator’s manual for additional information on engine overheating.
Check fuel level in tank. Check fuel pump operation. Check air filter for blockage. See engine operator’s manual for additional information.
Disconnect all loads and restart unit. Read frequency (Hz) in the LCD window on controller. Frequency should read 60 Hz. If frequency is above 60 Hz, engine speed will need to be adjusted. Contact John Deere to adjust speed.
Troubleshooting
This Page Intentionally Left Blank
44 MMG75D-100D Operating Manual 33701 C
Section 6 - Wiring Diagrams

AC WIRING - 3 POSITION VOLTAGE SELECTOR SWITCH

SEE DC WIRING DIAGRAM
FOR CT CONNECTIONS
5 AMP FUSE
ON REGULATOR
PM600
VOLTAGE
REGULATOR
P2 P1 T7 T9
F+ F-
A2
A1 VR1 VR2
50HZ 60HZ
BN BN/WT
RD BK WT BK
MAIN
CIRCUIT
BREAKER
BN/WT
BN
TO POWER ZONE
AVR PINS
L1
SHUNT
12VDC
BLK
TO POWER ZONE PIN 39
MECHANICAL LUGS
L2 L3
CT-3
CT-2CT-1
BLK
BLK
31 POS CONN2
DEUTSCH PLUG
RD BK
L0
GROUND
TO GEN FRAME
WIRES NOT USED IN
BUCK BOOST OPTION
TO POWER ZONE PIN 40
(T7)
PAIR BLK
PAIR BLK
(T9)
PAIR BLK
(L0)
L0
PAIR BLK
L1
L2
L3
2 3
GND
RD BK
T4
1
2
3
4
GRN/YEL GRN/YEL
GRN/YEL GRN/YEL GRN/YEL
BRN
BLK
BLK
BLK
BLK
BLK
BLK
59
10 14
6
78111215
T5
16
240V 50A
BREAKER
240V 50A
BREAKER
240V 50A
BREAKER
LT BLU
LT BLU LT BLU
LT BLU LT BLU
13
120V GFCI RECPT
120V 20A BRKER
BRN
BLK
BLK
BLK
BLK
BLK
BLK
21
17
18
22
1920232427
120V GFCI RECPT
240V 50A RCPT.
240V 50A RCPT.
240V 50A RCPT.
T9
25
26
28
SWITCH 15-20, 12-17,
120V 20A BRKER
T6 T8 T10 T11 T7 T1 T12
(3) JUMPER
WIRES ON PHASE
10-21
GENERATOR
T2
T3
GROUND
F-
F+
90497_A_05.19.15
TO
FRAME
33701 C MMG75D-100D Operating Manual 45
Wiring Diagrams

AC WIRING - 4 POSITION VOLTAGE SELECTOR SWITCH OPTION

5 AMP FUSE
ON REGULATOR
PM600
VOLTAGE
REGULATOR
F+ F-
VR1 VR2
50HZ 60HZ
BN
P2
BN/WT
P1 T7 T9
RD BK WT
A2
BK
A1
CIRCUIT
BREAKER
TO TB1 FUSED & SWITCHED
SEE DC PRINT
BN/WT
TO POWER ZONE PIN 39
BN
TO POWER ZONE
AVR PI NS
31 POS CONN2
DEUTSCH PLUG
31 POS CONN2
DEUTSCH PLUG
RED BLK
MECHANICAL LUGS
L2
L1
SHUNT
12VDC
BLK
BLK
CT-2CT-1
RD/BK
29
2
RED
3
BLK
GRN/YEL 14GA GRN/YEL 14GA
GRN/YEL 10GA GRN/YEL 10GA GRN/YEL 10GA
BLK BLK BLK
BLK BLK BLK
16
20 AMP
BRN
BRN
17 21 25
18 22 26
1920232427
G.F.I.
OUTLET
30
31
28
TP3A
BREAKER
BN/WT
3329
34
363532
TP3
BLK
50A
CIRCUIT
BLK
BL
RD
BRN/WHT
X
RED
37
38
39
40
G
W
Y
BLK
BLU
BLU
31 POS CONN2
DEUTSCH PLUG
L3
L0
BLK
BLK
CT-3
TP1
GND
GROUND
TO GEN FRAME
BLK
BLK
(T7)
BLK
(T9)
BLK
(L0)
TO POWER ZONE PIN 40
5913
1
TP2
61014
2
78111215
3
4
TP0
28
46 53
T12
T5
T6 T8 T2
T11
T7 T1 T9
T10
T3 T4
X
BLK
50A
CIRCUIT
BREAKER
81
RED
20 AMP
G.F.I.
OUTLET
G
W
Y
BLK
BLU
2
7
GENERATOR
CIRCUIT
BREAKER
GN/YL
VOLT REGULATION
RELAY
BRN
F-
F+
20 AMP20 AMP
G
X
W
Y
BLK
BLK
BLU
GROUND
TO
FRAME
BLU
50A
90472_A_05.19.15
46 MMG75D-100D Operating Manual 33701 C

AC WIRING OPTIONS

WIRE
TO
PLUG
EDISON
Wiring Diagrams
DVR
39
POWER ZONE
40
BN/WT
LUG
DOOR
31 PIN
CONN-2
DEUTSCH
21 PIN
CONN-1
DEUTSCH
21 PIN
CONN-2
DEUTSCH
PMG
31 PIN
21 PIN
BN/WT
3
CONTROL ONLY
ZONE
NON-POWER
BN
7
B
USED ON
S
USED ON
BN
F+
2
CONN-2
DEUTSCH
OR
P
CONN-1
DEUTSCH
BN
RD
4
F+
DVR 2000E+
BN/WT
OROR
AND
HIGHER
MMG235
AND
MMG185
LOWER
BN/WT
33
34
BN/WT
F-
ONLY
POWER ZONE
3
N
POWER ZONE POS 37
POWER ZONE POS 38
BK
BK
WT
F-
AUX +
AUX -
GN/YL
6
V
R
DOOR
USED ON
RECONNECT
UP
BKRDWT
WT
UP
DROOP OFF
E1
BK
TO T7
31 PIN
CONN-2
DEUTSCH
21 PIN
CONN-2
DEUTSCH
ZONE
SOME
MODELS
NON-POWER
GENERATOR
NON-POWER
ZONE MODELS ONLY
REMOTE VOLTAGE
ADJUSTMENT SWITCH
DOWN
CGND
E2
YL
DOWN
E3
RD
T1T2T3
L1
TO T9
POWER ZONE ONLY
15
OR
M
TO T8
BUCK TRANSFORMER
(NOT USED IN POWER ZONE)
HEATER
H1
GEN
HEATER
GEN
T4
L2
L0
T7
T9
BR
OR
T7
T9
TO GEN VOLT L3
TO 120V BREAKERS
VOLTAGE RELAY
BN
BN
2
BK
COM
34
1
POWER
BK
SPLICE
H3
HEATER
NEUTRAL
TO GEN VOLT L1
7
WHT
RELAY
BAR
GN
WT
SPLICE
H2
H4
BOLT
GENERATOR BOX
GROUND RING TO
DEDICATED
240V GEN
L1 L3L2
CIRCUIT
BREAKER
65
8
2
6
NO
5
78
BK
BK
BK
RD
NC
GROUND
GNDL0L1 L3L2
BLOCK
TO LUG
CAM LOCKS
ALT
CAM
LOCK
PANE L
GROUND
GNDL0L1 L3L2
BLOCK
TO LUG
CAM
LOCK
PANE L
H2 H4
X2X4 X1X3
BUCK XFORMER
H1 H3
NOTE: REPEAT ALT CAM LOCK FOR ADDITIONAL SETS.
L1 L3L2
CIRCUIT
BREAKER
TO T7
WT
BK
TO L0 TO L0
WT
90415_T_06.17.15
33701 C MMG75D-100D Operating Manual 47
Wiring Diagrams

PMG WIRING OPTION

T9
F+
2
31 PIN
CONN-2
DEUTSCH
P
21 PIN
CONN-1
DEUTSCH
GEN
F-
3
OR
N
BN
ZONE
POWER
CONTROL
BK
WT
REGULATOR
PM300 VOLTAGE
E3/4
6
F+ F- 7
3
E1
37
NOT CONNECTED TO
T9 FOR V-FLEX OR PM500
T7
T7 & T9 FOR V-FLEX
NOT CONNECTED TO
CONNECT TO CONN2 POS K OR
600V RELAY PIN4 WHEN EQUIPPED
CONNECT TO CONN2 POS L OR
600V RELAY PIN8 WHEN EQUIPPED
CONNECT TO CONN2 POS K OR
600V RELAY PIN4 WHEN EQUIPPED
V-FLEX ONLY
BN
T7
T9
BN/WT
LUG
BN/WT
ZONE
DOOR
NON-POWER
VOLTAGE
ADJUSTMENT
SEE POWER
ZONE OPTION
(2.5K, 2 WATT)
40
POWER
ZONE
CONTROL
BK
RD
39
ONLY
BN/WT
BK/WT
BN
ZONE
POWER
CONTROL
37
38
WT
BK
38
WT
BK
A1 A2
E3
T9
VR1 VR2 E2
F+ F-
E1 P1
P2
VR1 VR2
F+ F-
P1
T7
P2 A1 A2
31 PIN
DEUTSCH
21 PIN
DEUTSCH
21 PIN
DEUTSCH
PMG
7
CONN-2
B
CONN-1
S
CONN-2
BN
OR
AND
HIGHER
USED ON
MMG235
OR
AND
USED ON
MMG185
LOWER
ZONE
SOME
MODELS
USED ON
NON-POWER
BN/WT
6
V
R
BN/WT
33
RECONNECT
34
DOOR
(ALTERNATE)
PM500 VOLTAGE
REGULATOR
(ALTERNATE)
PM600 VOLTAGE
90672_ORG_06.19.15
REGULATOR
48 MMG75D-100D Operating Manual 33701 C

DC WIRING

MAIN
BREAKER
TO VOLTAGE REGULATOR SEE AC PRINT
TO
GND
BK
YLL0WT WT
OR
SHUNT
TO
GN/YL
GN/YL
GN/YL
FOR VREG CUTOUT
TO 3 POS LUG BLOCK T7
BAR
GND
RD/BK
BAR
323133
MSC
SCR H LB A SCR
N
RECONNECT/LUG DOOR
OR 31 POS DEUTSCH PIN 6 FOR PMG
SEE AC PRINT
L3
L2
L1
CT-3
WT
CT-2
WT
CT-1
WT
TO
BK/WT
5640 302928 57 50494847
TO EXPANSION MODULES
SHLD
CLR
BK
BN/WT
BN/WT
RD/BK
YL
WT
46454443 4241 3924 2322
BL
RD
BK
5455535251
TO
BAR
GND
GN/YL
YL/WT
OR/WT
BN/WT
RS485
TO DISPLAY
BAR
GND
STR
SCR
WVU N
COMCT4
CT2 CT3
CT1
L2 L3L1
S2
S1
OUTPUT
SHUNT TRIP
L3L2L1
NS1
L3S1L2S1
L1S1
BUS VOLTS
L1 LOAD
CURRENT
C
MPU
GEN
CLOSE
GEN VOLTS
GEN CURRENT
USB
V2
8660 ONLY
MODULE 7740
D
OUTPUT
V1
FLEXIBLE IF
J1939 IS USED
RS232
B
A
RS485
BK
CLR
CONTROL
PORT
PROGRAMMING
USB HOSTRJ45
ETHERNET
SPARE
AMB BEACON
RED BEACON
ALARM
FUEL TRANSFER
FAN CLUTCH
6 FET OUTPUTS
+VE
CRANK
FUEL
SCR
BATTERY
SHLD
POWER
SWITCH
LHSCR
ENGINE ECU
BA AB
O/P O/P
GOVERNOR AVR
JIHGFE
SPARE
LOAD SHED
OIL LEVEL
FUEL XFER ENABLE
LEAK DETECT
LUG DOOR
11 INPUTS
FORCE REGEN
INHIBIT REGEN
LOW COOLANT
REMOTE START
BCDEFGHI JK
RECONNECT DOOR
A
CHRG ALT
COMMON GROUND
AUX FUEL TANK SENDER
FUEL LEVEL (FLEXIBLE)
WATER TEMP
OIL PRESSURE
AB
-VE
+VE
RD/WT
RD/BK
RD/BK
RD/VI
RD/VI
Wiring Diagrams
CLR
BK
31 PIN
CONN 2
RD/BK
RD/BK
SEE
AC DWG
REGULATOR
BK/WT
TO
GND
TO VREG RELAY PIN 7
OPTIONAL-DVR
OPTIONAL
OPTIONAL
OPTIONAL
OPTIONAL
BAR
29
N.O.
PHASE
RD
28
YL
15
BK/WT
18
OR/YL
19
OR/WT
11
OR/BK
12
WT/BL
31
BL
30
BN/WT
6
BN
7
BK/WT
14
RD/VI
13
BK/WT
27
WT/RD
26
BK
3
F-
RD
2
F+
BK/WT
16
GY/BK
17
BK/WT
23
RD/WT
22
BK/WT
4
GY
5
BK/WT
8
1
WT/VI
BK/WT
25
RD/BK
24
BK/WT
21
GY/OR
20
VI/YL
10
RD/VI
9
SWITCH
4 POS
RD
YL
T8
BK/WT
BEACON
AMBER
OR/YL
BEACON
RED
OR/WT
ALARM
OR/BK
WT/BL
CT
405 &
465
SENSING
NEUTRAL
BL
BN/WT
PMG
BN
OPTIONAL
GND
XFER
FUEL
PUMP
PWR
OPTIONAL
BK/WT
LEAK
DETECT
OPTIONAL
WT/RD
F-
GEN
BK
F+
TO
GEN
RD
GY
BK/WT
GY/BK
BK/WT
RD/WT
BK/WT
BK/WT
WT/VI
BK/WT
RD/BK
BK/WT
GY/OR
VI/YL
RD/VI
OPTIONAL
CNO
OPTIONAL
OPTIONAL
B
A
LIGHT
INTERIOR
DOOR
(HELD
SWITCH
RECONNECT
FUEL
FILTER
HEATED
FAN
CLUTCH
GEN FIELD
LOW
CLOSED
NORMALLY)
22
C N
21
COOLANT
FUEL
LEVEL
SWITCH
E-STOP
WT
BK
12 13
OR/YL
OR/WT
OR/BK
GY/YL
TO VOLTAGE
REGULATOR
SEE AC PRINT
70
6968 71110983837363534 27 2625
676665646362616019181716 15 65431
WT/RD
OR/WT
GY/GN
GY/BL
GY/BK
GY/OR
GY
OR
BK/WT
WT/VI
RD/YL
RD/VI
VI/YL
TO
BK/WT
2
RD/BK
RD/BK
RD/BK
FU&SW
FUEL
RD/VI
RD/VI
RD/VI
MANUAL
BAR
BK/WT
CONTACT
VI/YL
RD/VI
RD/WT
RDRDRD
VI/YL
20A
1
TO
GND
HEATED
RD/WT
CNO
BAR
RD/BK
86
RD/WT
FILTER
RD/VI
15A
234
20A
LUG
87A
87
30
(HELD
DOOR
85
SPARE
CLOSED
NORMALLY)
BK/WT
TO
BAR
GND
FUSE
BLOCK
BK/WT
TO
GND
AUTO
BK/WT
GND
INHIBIT
BAR
GND
START
RD/YL
RD/WT
RD/WT
FUSED
TB1
BATT
RD
RD
RD
RD
RD
TO
INHIBIT REGEN SWITCH
1
2
TB3
START
REMOTE
SWITCH
SERVICE
RD/VI
RD
87
85
86
87A
BK/WT
TO
30
BAR
GND
RD
BAR
GY/YL
CLUTCH
TO
VOLTAGE
GY/OR
87
86
85
87A
30
FAN
RD/VI
POWER
TO DISPLAY
CLR
SHLD
F
U
CAN-LOW
CAN-SHIELD
BK
H
V
CAN-HIGH
X
N
K
L
P
M
TO
BAR
GND
BK
OR
S
R
E
J
BK
OR
RD
RD
A
D
T
RD
RD
30A
RD/VI
C
+
12V OR
ENGINE
G
W
RD
21 PIN
IGNITION
CONN1
FOR ATT GENERAC USE ANALOG EXPANSION MODULE.
NOTES:
1. TO ADD OPTIONAL REMOTE ANNUNCIATOR (COMMUNICATIONS)
2. TO ADD OPTIONAL ANALOG GAUGES USE ANALOG EXPANSION MODULE.
STARTERALT
RD
24 V
BATTERY
GND
90438_H_11.02.15
B
33701 C MMG75D-100D Operating Manual 49
Wiring Diagrams

DC WIRING OPTIONS

RD/BK
24
A
25A FUSE
FAN
GY/OR
20
CONN-2
W
TO
85
GY/OR
87
86
CLUTCH
FAN
RELAY
FUEL
PUMP
TRANSFER
DETECT
31 PIN
BAR
TO GND
BLK/WHT
ENABLE SW
FUEL TRANSFER
GRY/VIO
TO PZ CONTROL PIN 67
CLUTCH
BK/WT
21
31 PIN
OR
X
21 PIN
BO7
CTRL
GY/OR
30
87A
RD/VI
1
2
. .
. .
14
13
BK/WT
RELAY
FUEL XFER
86
RD/VI
87
85
87A
PANE L
CONTROL
LIGHT PZ
BK/WT
RD/BK
RD/WT
FUSED
FU&SW
TB1
BATT
FILTER
HEATER
BK/WT
25
31 PIN
CONN-2
OR
C
21 PIN
CONN-2
BK/WT
MTB
10
SPLICE
MTB
BAR
TO GND
RD/WT
NC
ESTOP
22
OR
1
MMG 405
RD/VI
86
RELAY
FUEL HEAT
87
87A
85
12 V
& 465 ONLY
30
BK/WT
+
RED
BATTERY
2A FUSE
CHARGE
SOLAR
FUEL
HEATED
TO GND
-
BLK
MODULE
PAN EL
FILTER
RD/BK
BAR
CONN-1
DEUTSCH
CONN-2
DEUTSCH
31 PIN
21 PIN
FLOAT
CHARGER
SOLAR BATTERY
DEUTSCH
LEAK
BI4
?
MAY
VARY
T
RD/VI
SPLICE
RD
SWITCH
RD
CONN-2
DEUTSCH
TO GND
BK/WT
BAR
TO GND
BAR
GY/VI
30
MTB PIN 1
TO PZ CONTROL PIN 9
RD
FAN
CLUTCH
OR
(FUEL)
ESTOP ON UNITS UP TO MMG55
FUEL
PUMP PZ
TRANSFER
RD/VI
15A
TO TB1 (BATT)
BLK
-
+
BATTERY
DISCONNECT
RELAY BOARD
12 V
PLUG
BATTERY
BATTERY
DISCONNECT
RD
BK
BK
BK
+
BO5
BO4
D+
LABEL
REMOTE
COMMUNICATION
REMOTE COMMUNICATION
RELAY BOARD
WT
+
COM
4
-
NO
+
COM
3
-
NO
+
COMCOM
2
-
NO
+
1
-
BK
BO7-BO6
NO
7
6
8
5
9
4
WT 8
10
11
WT 12
12
WT 4
WT 6
2
3
WT
2
1
1
START
REMOTE
GY/OR
BI2
LIGHT 2
INTERIOR
LIGHT 1
INTERIOR
31 PIN
DEUTSCH
RD/BK
CONN-2
BK
BK/WT
23
BK/WT
TB1
CABINET
INTERIOR
LIGHT PZ
RD/BK
22
RD/BK
RD/WT
FUSED FU&SW
BATT
90416_N_11.20.14
50 MMG75D-100D Operating Manual 33701 C

LOW OIL LEVEL WIRING OPTION

SWITCH
WT
RD
SPLICE
WT/BL
CONN-2
DEUTSCH
21 PIN
U
CONN-2
DEUTSCH
31 PIN
26
CONTROLLER PIN 66 (7310)
WT/BL
CONTROLLER PIN 68 (PZ)
Wiring Diagrams
SPLICE

BATTERY CHARGER WIRING OPTION

EDISON PLUG
YEL/GRN
CONN-2
DEUTSCH
21 PIN
F
BLU
BRN
CONN-2
DEUTSCH
31 PIN
BK/WTBK/WT
27
16/3
BATTERY
CHARGER
RED
BLK
90611_ORG_12.03.14

ENGINE HEATER WIRING OPTION

EDISON PLUG
WT
GN BK
+
12 V
BATTERY
ENGINE HEATER
-
90593_ORG_10.29.14
90594_ORG_10.29.14
33701 C MMG75D-100D Operating Manual 51
Wiring Diagrams

WIRING BLOCK DIAGRAM - DEDICATED 12 LEAD GENERATORS OPTION

T1
L7
L9
L3 L2 L1
TO CONTROL BOX
HIGH DELTA
240/120V 3PH
LO
T4 T7
T2
T8 T5
T3 T6
T9
T11
T12 T10
L7
L9
L3 L2 L1
TO GENERATOR
120V 3PH
TO CONTROL BOX
LOW DELTA
LO
T7 T6
T1
T8 T4 T2
T9 T5 T3
T12
T10
T11
TO GENERATOR
L3 L1
TO CONTROL BOX
480/240V 1 PH
HIGH ZIG ZAG
LO
L7
L9
L3 L2 L1
HIGH WYE
480/277V 3PH
TO CONTROL BOX
LO
T2 T8 T5
T7 T4
T1
T6 T9 T3
T4 T7
T1
T2 T5 T8 T6 T9 T3
T12
T11
T10
T12
T11
T10
T7
L7
L9
L3 L1
TO GENERATOR
240/120V 1 PH
TO GENERATOR
208/120V 3PH
TO CONTROL BOX
LOW ZIG ZAG
LO
L7
L9
L3 L2 L1
LOW WYE
TO CONTROL BOX
LO
T1
T12 T8 T6 T2
T9 T3
TO GENERATOR
T11
T10 T5 T4
T7
T1
T8 T2
T9 T3
T12
T11
TO GENERATOR
T10 T6 T5 T4
90302_A_11.06.12
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.
52 MMG75D-100D Operating Manual 33701 C

TRAILER LIGHTS WIRING

TRAILER PLUG
GN
BK
WT
WT
WT
BK
WT
BK
BK
WT
BK
WT
WT
BK
RD
WT
RD
BK
WT
GN
BN
WT
BN
BN
WT
BN
WT
YL
BN
WT
TRAILER PLUG
GN
YLYLBNBNBNBNWT
Wiring Diagrams
AMBER
MARKER
LAMP
RED
MARKER
LAMP
BK
WT
BK
WT
BN
WT
BN
WT
BK
WT
BK
WT
AMBER
MARKER
LAMP
RED
MARKER
LAMP
BK
WHITE
MARKER
LAMP
STOP-TURN
SIGNAL LAMP
(LEFT)
33701 C MMG75D-100D Operating Manual 53
WT
RD
BK
WT
BN
WT
YL
BN
WT
GN
BN
WT
RD
BK
WT
STOP-TURN
SIGNAL LAMP
(RIGHT)
90431_ORG_09.11.12
Wiring Diagrams

WIRING HARNESS - ELECTRIC BRAKE OPTION

SPLICE
BRAKE
BRAKE BRAKE
SPLICE
SPLICE
SPLICE
SPLICE
SPLICE
SPLICE
BRAKE
BRAKE
BRAKE
SPLICE
SPLICE
SPLICE
SPLICE
SPLICE
WT
WT
WT
BL
BL
BL
SINGLE AXLE
TANDEM AXLE
TRI-AXLE
FRAME GND
WT
BATTERY
BL
BKBL
SPLICE
SPLICE
BL
WT BK
BREAKAWAY
SWITCH
90286_E_03.18.14
54 MMG75D-100D Operating Manual 33701 C
Section 7 - Options & Accessories

VISCOUS FAN CLUTCH OPTION

The viscous (cooling) fan clutch option allows the engine cooling fan to engage at lower speeds and disengage at higher speeds, increasing cooling system efficiency. The cooling fan will engage at full speed when the coolant temperature rises. When the fan is operating at full speed, it will switch to a slower speed when the coolant temperature drops. There will be an audible difference when the engine cooling fan switches speeds. Depending on unit model, the temperature ranges vary between 170°F and 200°F (77°C and 93°C).

GENERATOR CAM LOCK CONNECTIONS OPTION

The unit may be equipped with cam lock connections, located below the receptacles. These receptacles provide connection points for the attachment of external loads to the generator. A large decal on the inside of the connection lug door details the proper connections for selected voltages.
WARNING
Only qualified service personnel may install, operate and maintain this equipment.
Failure to follow proper installation requirements could result in death, serious injury,
and damage to equipment or property. (000182)
WARNING
Before any connections are made to the generator, make sure that the main circuit breaker and the Control Power switch are OFF (O) and the negative (-) battery cable is disconnected. Potentially lethal voltages may be present at the generator connec-
tion lugs.
DANGER
IMPROPER OR INCORRECT CONNECTIONS TO A BUILDING’S ELECTRICAL SYSTEM CAN CAUSE POTENTIALLY LETHAL VOLTAGE TO BACKFEED INTO UTILITY LINES. THIS MAY RESULT IN INJURY OR ELECTROCUTION TO UTILITY WORKERS NEARBY.
MAKE SURE THE GENERATOR IS SUPPLYING POWER TO AN ISOLATED OBJECT
OR BUILDING THAT IS NOT CONNECTED TO ANY UTILITY LINES.
Connections should be made by plugging power cables equipped with series 16 taper nose 400A/600V cam lock plugs into the cam lock receptacles. Secure the connection by rotating the plug a 1/2 turn to the right.
L1 L2
L3
N (Neutral)
G (Ground)
Black Red
Blue
White
Green
01894
Figure 7-15. Cam Lock Connections
33701 C MMG75D-100D Operating Manual 55
Options & Accessories
A ground connection is located on the far right of the cam lock panel. The unit MUST be connected to 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 secondary power source or where bonding is completed elsewhere in the circuit. Installation should be in compliance with the national electrical code (NEC), state and local regulations.
56 MMG75D-100D Operating Manual 33701 C

Service Log

OIL GRADE: _____________________________________ BRAND: __________________________________
COOLANT MIXTURE: _____________________________ BRAND: __________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
Date
Hours to
Service
Oil Level
Coolant
Level
Date
Hours to
Service
Oil Level
Coolant
Level
57

Notes

___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
58

Notes

___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
59

Notes

___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
60
Loading...