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)

ii

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

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

n

t

r

o

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

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

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

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

10

0

480V/277V 3-Phase

To ta l

0.0

%

0.00

%

480V/277V 3-Phase

Total Generator

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

0

StatusScheduleI/OAlarmsEngine Generator

Energy Generator

0.0

07:10

kWh+

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

480V/277V 3-Phase

%

0.0

%

0.0

300

400

500

600 0

0.0

Total Generator

kW

0.0

kVA

0.0

kVAr

pf

0.0

30 40

20

10

FreqVoltVoltVolt

70

0.0

0.00

0.0

StatusScheduleI/OAlarmsEngine Generator

07:10

kWh+

kVAh

kVArh

50

60

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

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

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

kVA

kVAr

0.0

%

0.0

0.00

pf

%

0.0

07:10

kWh+

0.0

kVAh

kVArh

0.0

StatusScheduleI/OAlarmsEngine Generator

00405

07:10

kWh+

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

0.00

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

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

Oil

Grease

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

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

(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

59

10 14

6

78111215

T5

16

240V 50A

BREAKER

240V 50A

BREAKER

240V 50A

BREAKER

LT BLU

LT BLU LT BLU

13

120V GFCI RECPT

120V 20A BRKER

BRN

BLK

21

17

18

22

1920232427

120V GFCI RECPT

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

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

16

20 AMP

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

31 POS CONN2

DEUTSCH PLUG

L3

L0

BLK

CT-3

TP1

GND

GROUND

TO GEN FRAME

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

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

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

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

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

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

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/VI

Wiring Diagrams

CLR

BK

31 PIN

CONN 2

RD/BK

SEE

AC DWG

REGULATOR

BK/WT

TO

GND

TO VREG RELAY PIN 7

OPTIONAL-DVR

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

WT/VI

BK/WT

RD/BK

BK/WT

GY/OR

VI/YL

RD/VI

OPTIONAL

CNO

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

FU&SW

FUEL

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

FUSED

TB1

BATT

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

A

D

T

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

DISCONNECT

RD

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

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

BK

WT

BK

WT

BK

WT

BK

RD

WT

RD

BK

WT

GN

BN

WT

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

BRAKE

SPLICE

WT

BL

SINGLE AXLE

TANDEM AXLE

TRI-AXLE

FRAME GND

WT

BATTERY

BL

BKBL

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

Generac Power Systems MAGNUM MMG75D, MAGNUM MMG100D Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

SAFETY NOTES

OPERATING SAFETY

ENGINE SAFETY

SERVICE SAFETY

TOWING SAFETY

REPORTING TRAILER SAFETY DEFECTS

SAFETY SYMBOL SUMMARY

SPECIFICATIONS

Unit Dimensions

UNIT SERIAL NUMBER LOCATIONS

COMPONENT LOCATIONS

CONTROL PANEL

POWER ZONE™ GEN CONTROLLER

Controller Features and Functions

Home Button

Engine Button

Generator Button

Voltage Adjust Button

Alarm Mute Button

Auto/Manual Mode Button

Navigation Buttons

Control Power Switch

Engine Start Button

Engine Stop/Reset Button

The Liquid Crystal Display (LCD)

Maintenance Screens

Generator Summary

Engine Tab

Generator Tab

Alarms Tab

Input/Output Tab

Schedule Tab

Status Tab

Generator Monitoring

Engine Monitoring

Diesel Exhaust Filter Monitoring

Controller Information Displays, Functions, and Reset

BELT TENSIONERS

FRONT HOOD OPERATION

To Open the Front Hood

To Close the Front Hood

PRESTART CHECKLIST

MANUALLY STARTING THE UNIT

AUTO (REMOTE) STARTING THE UNIT

TRANSFER SWITCH

DERATING FOR ALTITUDE

GENERATOR OUTPUT CONNECTIONS

FINE VOLTAGE ADJUSTMENT

VOLTAGE SELECTOR SWITCH

VOLTAGE REGULATOR

CUSTOMER CONVENIENCE RECEPTACLES

MAIN CIRCUIT BREAKER

EXHAUST FILTER CLEANING OPERATIONS

Disabling Automatic (Auto) Exhaust Filter Cleaning

Force a Manual Exhaust Filter Cleaning

Enable Exhaust Filter Cleaning

AUTO EXERCISE TIMER

Accessing the Configuration Menu

Set the Controller Clock

Set the Schedule

Set the Unit to Auto Mode

SHUTTING DOWN THE UNIT

EMERGENCY STOP SWITCH

ECU OVERRIDE SWITCH

TOWING THE UNIT

LIFTING THE UNIT

EMISSIONS INFORMATION

DAILY WALK AROUND INSPECTION

GENERAL MAINTENANCE

BASIC MAINTENANCE SCHEDULE

ENGINE BREAK-IN REQUIREMENTS

RESETTING THE MAINTENANCE ALARMS

EXHAUST FILTER SERVICE REQUIREMENTS

CHECKING GENERATOR DRIVE PLATE TORQUE

JACK MAINTENANCE