Magnum MMG 125, MMG 180, MMG 155, MMG 230 Operating Manual

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DIESEL GENERATORS

MMG 125 • MMG 155 MMG 180 • MMG 230

OPERATING MANUAL

230

Page 2

INTRODUCTION

This manual provides information and procedures to safely operate and maintain the engine and generator . For your own safety and protection from physical injury , carefully read, understand, and observe the safety instructions described in this manual. The information contained in this manual was based on machines in production at the

time of publication. Magnum Products LLC reserves the right to change any portion of this information without notice.

DO NOT MODIFY or use this equipment for any application other than which it was designed for .

Magnum Products LLC recommends that a trained and licensed professional perform all electrical wiring and testing functions. Any wiring should be in compliance with the United S t ates National Electric Code (NEC), state and local codes and Occupational Safety and Health Association (OSHA) guidelines.

Keep a copy of this manual with the unit at all times. Additional copies are available from Magnum Product s LLC, or can be found at www.m-p-llc.com. An engine operators manual was also supplied with the unit at the time of shipment from the factory . The manual provides detailed operation and maintenance procedures for the engine. Additional copies of the engine operators manual are available from the engine manufacturer.

MAGNUM 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.m-p-llc.com

WHEN CALLING FOR P ARTS OR TECHNICAL SER VICE INFORMATION,

PLEASE HA VE YOUR UNIT MODEL NUMBER AND SERIAL NUMBER READY.

Engine Make: Engine Serial Number: Engine Model Number: Generator Make: Generator Model Number: Generator Serial Number: Unit Model Number: Unit Serial Number:

Diesel engine exhaust and some of its constituents are known to the state

of California to cause cancer, birth defects and other reproductive harm.

WARNING

CALIFORNIA PROPOSITION 65 W ARNING:

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T ABLE OF CONTENTS

INTRODUCTION........................................................................................................................... 2

TABLE OF CONTENTS................................................................................................................ 3

SAFETY NOTES .......................................................................................................................... 4

OPERATING SAFETY.................................................................................................................. 4

ENGINE SAFETY.......................................................................................................................... 5

ELECTRICAL SAFETY................................................................................................................. 5

TOWING SAFETY........................................................................................................................ 6

REPORTING TRAILER SAFETY DEFECTS................................................................................. 6

UNIT SERIAL NUMBER LOCATIONS........................................................................................... 7

SAFETY SYMBOL SUMMARY...................................................................................................... 8

SPECIFICA TIONS................................................................................................................. 9 - 12

UNIT DIMENSIONS .....................................................................................................................13

SERVICE LOCA TIONS ............................................................................................................... 14

MAIN CONTROL PANEL FEATURES......................................................................................... 15

MAGNUM DIGIT AL CONTROLLER (MDC)......................................................................... 16 - 17

GENERATOR MONITORING.......................................................................................................17

ENGINE MONITORING ...................................................................................................... 18 - 19

FINE VOL TAGE ADJUSTMENT.................................................................................................. 19

GENERATOR START UP.............................................................................................................20

PRE-START CHECKLIST ............................................................................................................20

MANUAL STARTING OF THE GENERA TOR ...................................................................... 20 - 22

AUTO (REMOTE) STARTING OF THE GENERATOR.................................................................22

SHUTTING DOWN THE GENERATOR .......................................................................................22

MDC CONTROLLER INFORMA TION DISPLAYS, FUNCTIONS AND RESET ............................23

MDC CONTROLLER - GENERATOR OPERATIONAL STATUS..................................................23

MDC CONTROLLER - ALARM MANAGEMENT..........................................................................23

MDC CONTROLLER LIST OF POSSIBLE ALARMS WITH DESCRIPTIONS ..................... 24 - 25

JOHN DEERE ECU INFORMA TION DISPLAYS AND FUNCTIONS............................................25

MDC CONTROLLER - HISTORY.................................................................................................26

ADJUSTING THE DISPLAY BACKLIGHTING..............................................................................26

RESETTING THE “TIME TO SERVICE” REMINDER ..................................................................27

TROUBLESHOOTING AUTOMA TIC SHUTDOWN CONDITIONS ....................................... 27- 28

GENERATOR OUTPUT CONNECTION LUGS............................................................................29

VOLTAGE SELECTOR SWITCH ................................................................................................. 30

4 POSITION VOLTAGE SELECTOR SWITCH (OPTIONAL) .......................................................31

CHANGING OUTPUT VOLTAGE (MMG 230) ..............................................................................32

EMERGENCY STOP SWITCH.................................................................................................... 33

MAIN CIRCUIT BREAKER .......................................................................................................... 33

VOL TAGE REGULATION............................................................................................................ 33

CUSTOMER CONVENIENCE OUTLETS ................................................................................... 34

DERATING FOR ALTITUDE.........................................................................................................34

REMOTE ST ART TERMINAL BLOCK................................................................................. 35 - 36

ENGINE AND GENERATOR MAINTENANCE .............................................................................36

ENGINE BREAK IN REQUIREMENTS ........................................................................................36

DAIL Y MAINTENANCE CHECKS.................................................................................................37

LIFTING THE GENERAT OR ........................................................................................................37

TOWING THE TRAILER ..............................................................................................................38

TRAILER WHEEL BEARINGS .....................................................................................................38

AC WIRING DIAGRAM MMG 125, 155, 180 ............................................................................... 39

AC WIRING DIAGRAM MMG 230................................................................................................40

DC WIRING DIAGRAM MMG 125, 155, 180................................................................................41

DC WIRING DIAGRAM MMG 230 ...............................................................................................42

AC WIRING DIAGRAM MMG 125, 155, 180 With 4 position voltage selector switch .................. 43

AC WIRING DIAGRAM MMG 230 With 4 position voltage selector switch.................................. 44

TRAILER LIGHTS WIRING DIAGRAM ........................................................................................45

NOTES.........................................................................................................................................46

SERVICE LOG .............................................................................................................................47

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SAFETY NOTES

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

This manual contains DANGERS, WARNINGS, CAUTIONS, NOTICES and NOTES which must be followed to prevent the possibility of improper service, damage to the equipment, personal injury or death. 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, may result in minor or moderate injury.

DANGER

INDICATES A HAZARDOUS SITUATION WHICH, IF NOT AVOIDED,

WILL RESULT IN DEATH OR SERIOUS INJURY.

WARNING

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury.

CAUTION

NOTICE

Indicates a hazardous situation which, if not avoided,

may result in property or equipment damage.

Note: Notes contain additional information important to a procedure and will be found within the regular text body of this manual.

OPERATING SAFETY

Before using the generator be sure you read and understand all of the instructions! This equipment was designed for specific applications; DO NOT modify or use this equipment for any application other than which it was designed for. Equipment operated improperly or by untrained personnel can be dangerous! Read the operating instructions and familiarize yourself with the location and proper use of all instruments and controls. Inexperienced operators should receive instruction from someone familiar with the equipment before being allowed to operate or set up the generator. The following points should be practiced at all times:

• The area immediately surrounding the generator should be dry, clean, and free of debris.

• NEVER start a unit in need of repair.

• Make certain the generator is securely fastened to a good earthen ground before use.

• NEVER operate the generator if any of the following conditions exist during operation:

- Noticeable change in engine speed.

- Loss of electrical output.

- Equipment connected to the generator overheats.

- Sparking occurs.

- Engine misfires or there is excessive engine/generator vibration.

- Operating on a combustible surface.

- Protective covers are loose or missing.

- If the ambient air temperature is above 1 10° F.

• Make sure slings, chains, hooks, ramps, jacks, and other types of lifting devices are attached securely and have enough weight-bearing capacity to lift or hold the equipment safely. Always remain aware of the position of other people around you when lifting the equipment.

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ENGINE SAFETY

Internal combustion engines present special hazards during operation and fueling! Failure to follow the safety guidelines described below could result in severe injury or death. Read and follow all safety warnings described in the Engine Operator's Manual. A copy of this manual was supplied with the unit when it was shipped from the factory.

• DO NOT run the engine indoors or in an area with poor ventilation unless exhaust hoses are used. Diesel 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 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.

• DO NOT touch or lean against hot exhaust pipes or engine cylinders.

• DO NOT clean air filter with gasoline or other types of low flash point solvents.

• DO NOT remove engine coolant cap while the engine is hot.

• DO NOT operate the unit without a functional exhaust system. Prolonged exposure to sound levels

in excess of 85dB(A) can cause permanent hearing loss. Wear hearing protection when working around a running engine.

• Keep hands, feet and loose clothing away from moving parts on the generator and engine.

• Keep area around exhaust pipes and air ducts free of debris to reduce the chance of an accidental

fire.

• Batteries contain sulfuric acid which can cause severe injury or death. Sulfuric acid can cause eye damage, burn flesh or eat holes in clothing. Protective eye wear and clothing are necessary when working on or around the battery. Always disconnect the NEGATIVE (-) battery cable from the corresponding terminal before performing any service on the engine or other components.

ELECTRICAL SAFETY

The unit is powered by a generator driven by a diesel engine. While the engine is running, potentially lethal voltages are present at the 120V Ground Fault Circuit Interrupt (GFCI) outlets and the 240V twist lock outlets located on the control panel, and at the connection lugs and cam lock receptacles. Failure to follow the safety guidelines described below could result in severe injury or death.

• Only a qualified and licensed electrician should make connections to the generator.

• NEVER wash the unit with any high pressure hoses or power washers.

• NEVER start the unit under load. The circuit breakers must be in the “OFF” position when starting

the unit in MANUAL mode. The circuit breakers can be in the “ON” position only when started in the AUTO mode. A transfer switch must be used in the AUTO mode to deflect the load upon start up.

• ALWAYS disconnect the NEGATIVE (-) battery cable from the corresponding terminal before performing any service on the engine, generator or any other components. Remove the NEGATIVE (-) battery cable from the corresponding terminal if the unit is to be stored or transported.

• ALWAYS use extreme caution when servicing this unit in damp conditions. Do not service the unit if your skin or clothing is wet. Do not allow water to collect around the base of the unit.

• ALWAYS connect the unit to a good earthen ground before use. Follow any local, state, or United States National Electric Code (NEC) guidelines.

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TOWING SAFETY

Towing a trailer requires care! Both the trailer and vehicle must be in good condition and securely fastened to each other to reduce the possibility of an accident. Also, some states require that large trailers be registered and licensed. Contact your local Department of Transportation office to check on license requirements for your particular unit.

• Check that the hitch and coupling on the towing vehicle are rated equal to, or greater than, the trailer's "gross vehicle weight rating" (GVWR).

• Check tires on trailer for tread wear, inflation, and condition.

• Inspect the hitch and coupling for wear or damage. NEVER tow trailer using defective parts!

• Make sure the trailer hitch and the coupling are compatible. Make sure the coupling is securely

fastened to the vehicle.

• Connect safety chains in a crossing pattern under the tongue and attach the breakaway cable TO THE REAR BUMPER OF THE TOWING VEHICLE. Do not attach the cable to the trailer hitch.

• Make sure directional and brake lights on the trailer are connected and working properly.

• Check that the lug nuts holding the wheels on are tight and that none are missing.

• Maximum recommended speed for highway towing is 45 m.p.h. Recommended off-road towing

speed is not to exceed 10 m.p.h. or less depending on terrain.

Before towing the trailer, check 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 surge brakes or electric surge brakes. Check the operation of the brakes by braking the vehicle at a slow speed before entering traffic. Both the trailer and the vehicle should brake smoothly . If the trailer seems to be pushing, check the level in the surge brake fluid reservoir.

When towing, maintain extra space between vehicles and avoid soft shoulders, curbs and sudden lane changes. If you have not pulled a trailer before, practice turning, stopping, and backing up in an area away from heavy traffic.

A film of grease on the coupler will extend coupler life and eliminate squeaking. Wipe the coupler clean and apply fresh grease each time the trailer is towed.

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 Traf fic Safety Administration (NHTSA) in addition to notifying Magnum 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 individual problem between you, your dealer, or Magnum Product s LLC.

To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-888-327-4236 or by fax at: (202)-366-

7882. Additional contact information can be found at: www.nht sa.dot.gov.

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UNIT SERIAL NUMBER LOCATIONS

Refer to the locations illustrated below to find the unit ID tag, V.I.N. tag and trailer ID tag on your unit. Important information, such as the unit serial number, model number and Vehicle Identification Number (V.I.N.) for your trailer are found on these tags. Record the information from these tags, so it is available if the tags are lost or damaged. When ordering parts or requesting technical service information, you may be asked to specify this information.

UNIT ID Tag

(Located on control panel)

PRODUCTS LLC

1 Phase

FOR ELECTRICAL

EQUIPMENT ONLY.

POUR MATERIAL

ELECTRIQUE SEULEMENT.

V.I.N. Tag

KPA(PSI/LPC)

DATE: COLD INFL. PRESS./PRESS.

DE GONF A FROID

SGL/DUAL

MANUFACTURED BY/FABRIQUE PAR: MAGNUM PRODUCTS LLC

GVWR/PNBV:

GAWR/PNBE TIRE/PNEU RIM/JANTE

THIS VEHICLE CONFORMS TO ALL APPLICABLE STANDARDS PRESCRIBED UNDER THE CANADIAN MOTOR VEHICLE SAFETY REGULATIONS IN EFFECT ON THE DATE OF MANUFACTURE. / CE VEHICULE EST CONFORME A TOUTES LES NORMES QUI LUI SONT APPLICABLES EN VERTU DU REGLEMENT SUR LA SECURITE DES VEHICULES AUTOMOBILES DU CANADA EN VIGUEUR A LA DATE SA FABRICATION.

V.I.N./N.I.V.: 00000000000000000

TYPE/TYPE DE VEHICULE: TRAILER

THIS VEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL MOTOR VEHICLE SAFETY STANDARDS (FMVSS) IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE.

Trailer ID Tag

MADE IN USA

215 Power Drive Berlin, WI 54923 1-800-926-9768

Model

Serial Number

Mfg. Code

lbs

rpm hz amb. temp.

RATING: CONT. STAND BY

3 Phase

KVA

LR 114630-1

MODEL

SERIAL NUMBER 000000 kg lbs MADE IN USA

MAGNUM PRODUCTS LLC

BERLIN, WI 54923 USA

(800) 926-9768

Page 8

SAFETY SYMBOL SUMMARY

This equipment has been supplied with numerous safety and operating decals. These decals provide important operating instructions and warn of dangers and hazards. Replace any missing or hard-to-read decals and use care when washing or cleaning the unit. Below is a summary of the intended meanings for the symbols used on the decals.

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.

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.

Stop engine before fueling.

Hearing protection required while operating unit with doors open.

Lift here only.

Engine running.

Read and understand the supplied operator’s manual before operating unit.

Unit electrical ground.

Fire/explosion hazard; Keep open flames away from unit.

Burn/scald hazard; pressurized steam.

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SPECIFICATIONS

Read this manual carefully before attempting to use this generator. The potential for property damage, personal injury or death exists if this equipment is misused or installed incorrectly. Read all of the manuals included with this unit. Each manual details specific information regarding items such as set up, use and service requirements.

Specifications are subject to change without notice.

MAGNUM MODEL MMG 125 MMG 125 Super Start (SS) Engine

Make/Brand.............................................................John Deere .................................. John Deere

Model ......................................................................PE6068TF275 ............................. PE6068TF275

Horsepower - prime hp (kW) ..................................150 (112) ..................................... 150 (112)

Horsepower - standby hp (kW) ..............................165 (123) ..................................... 165 (123)

Operating Speed rpm .............................................1800............................................. 1800

Displacement in

Cylinders - qty .........................................................6................................................... 6

Fuel Consumption - 100% prime gph (Lph)...........7.7 (29.1) .....................................7.7 (29.1)

Battery Type............................................................Group 24...................................... Group 24

Battery Voltage (Quantity per Unit).........................12V (1)......................................... 12V (1)

Battery Rating .........................................................1000 CCA .................................... 1000 CCA

Generator

Make/Brand.............................................................Marathon Electric ........................ Marathon Electric

Model ......................................................................363PSL1661................................ 431PSL6206

Type, Insulation .......................................................Brushless, H ................................Brushless, H

(L) ...............................................415 (6.8) ...................................... 415 (6.8)

Generator Set (Engine/Generator)

3Ø - Standby kW (kVA) ..........................................108 (135) ..................................... 107 (134)

Amps - 3Ø St andby 480V (208V) A ........................162 (375) ..................................... 161 (372)

3Ø - Prime kW (kV A ) ..............................................99 (124) .......................................97 (121)

Amps - 3Ø Prime 480V (208V) A............................149 (344) ..................................... 146 (336)

1Ø - Standby kW (kVA) ..........................................97 (97) ......................................... 105 (105)

Amps - 1Ø St andby - 240V A..................................404............................................... 438

1Ø - Prime kW (kV A ) ..............................................90 (90) .........................................95 (95)

Amps - 1Ø Prime - 240V A......................................375............................................... 396

Frequency Hz..........................................................60................................................. 60

Power Factor...........................................................1 (1Ø), 0.8 (3Ø) ...........................1 (1Ø), 0.8 (3Ø)

Sound dB(A) 23 ft @ prime ...................................68................................................. 68

Weights

Dry Weight, Skid Mounted

Operating Weight, Skid Mounted lbs (kg) ..............7474 (3390) ................................. 7946 (3604)

Dry Weight, Trailer Mounted* lbs (kg) ....................7130 (3234) .................................7602 (3448)

Operating Weight, Trailer Mounted* lbs (kg)..........8870 (4023) ................................. 9342 (4237)

*Weights reflect units equipped with standard trailer only. Consult factory for custom trailer weights.

Capacities

Fuel Tank Volume gal (L) .......................................256 (969) .....................................342 (1295)

Usable Fuel Volume gal (L)....................................228 (863) .....................................313 (1185)

Coolant (incl. engine) qt (L)....................................42.0 (39.7) ................................... 42.0 (39.7)

Oil (incl. filter) qt (L)................................................18.0 (17.0) ................................... 18.0 (17.0)

Maximum Run Time hrs .........................................30................................................. 41

AC Distribution

Circuit Breaker Size ................................................450............................................... 450

Voltage Selection....................................................3 Position Switch (lockable) ........ 3 Position Switch (lockable)

Voltage Regulation..................................................+/- 1% .......................................... +/-1%

Voltages A vailable 1Ø.............................................120, 139, 208, 220, 240, 277 ......120, 139, 208, 220, 240, 277

Voltages A vailable 3Ø.............................................208, 220, 440, 480 ...................... 208, 220, 440, 480

lbs (kg) ........................5734 (2601) ................................. 6206 (2815)

Trailer

Number of Axles .....................................................2................................................... 2

Capacity - Axle Rating lbs (kg) ..............................6000 (2722) .................................6000 (2722)

Tire Size in..............................................................16................................................. 16

Brakes.....................................................................Surge ........................................... Surge

Hitch - Standard......................................................3" Ring......................................... 3" Ring

Maximum Tire Pressure psi ....................................75................................................. 75

Page 10

SPECIFICATIONS

Specifications are subject to change without notice.

MAGNUM MODEL MMG 155 MMG 155 Super Start (SS) Engine

Make/Brand.............................................................John Deere .................................. John Deere

Model ......................................................................PE6068HF275 .............................PE6068HF275

Horsepower - prime hp (kW) ..................................200 (149) ..................................... 200 (149)

Horsepower - standby hp (kW) ..............................220 (164) ..................................... 220 (164)

Operating Speed rpm .............................................1800............................................. 1800

Displacement in

Cylinders - qty .........................................................6................................................... 6

Fuel Consumption - 100% prime gph (Lph)...........9.8 (37.1) .....................................9.8 (37.1)

Battery Type............................................................Group 31...................................... Group 31

Battery Voltage (Quantity per Unit).........................12V (1)......................................... 12V (1)

Battery Rating .........................................................1000 CCA ....................................1000 CCA

Generator

Make/Brand.............................................................Marathon Electric ........................ Marathon Electric

Model ......................................................................363PSL1607................................ 432PSL6210

Type, Insulation .......................................................Brushless, H ................................Brushless, H

(L) ...............................................415 (6.8) ...................................... 415 (6.8)

Generator Set (Engine/Generator)

3Ø - Standby kW (kVA) ..........................................135 (169) ..................................... 146 (183)

Amps - 3Ø St andby 480V (208V) A ........................203 (468) ..................................... 220 (508)

3Ø - Prime kW (kV A ) ..............................................125 (156) .....................................132 (165)

Amps - 3Ø Prime 480V (208V) A............................188 (434) ..................................... 198 (458)

1Ø - Standby kW (kVA) ..........................................100 (100) ..................................... 143 (143)

Amps - 1Ø St andby - 240V A..................................417............................................... 596

1Ø - Prime kW (kV A ) ..............................................95 (95) .........................................130 (130)

Amps - 1Ø Prime - 240V A......................................396............................................... 542

Frequency Hz..........................................................60................................................. 60

Power Factor...........................................................1 (1Ø), 0.8 (3Ø) ...........................1 (1Ø), 0.8 (3Ø)

Sound dB(A) 23 ft @ prime ...................................68................................................. 68

Weights

Dry Weight, Skid Mounted

Operating Weight, Skid Mounted lbs (kg) ..............7566 (3432) ................................. 8308 (3768)

Dry Weight, Trailer Mounted* lbs (kg) ....................7222 (3276) .................................7964 (3612)

Operating Weight, Trailer Mounted* lbs (kg)..........8962 (4065) ................................. 9704 (4402)

*Weights reflect units equipped with standard trailer only. Consult factory for custom trailer weights.

Capacities

Fuel Tank Volume gal (L) .......................................256 (969) .....................................256 (969)

Usable Fuel Volume gal (L)....................................228 (863) .....................................228 (863)

Coolant (incl. engine) qt (L)....................................42.0 (39.7) ................................... 42.0 (39.7)

Oil (incl. filter) qt (L)................................................33.0 (31.2) ................................... 33.0 (31.2)

Maximum Run Time hrs .........................................23................................................. 23

AC Distribution

Circuit Breaker Size ................................................600............................................... 600

Voltage Selection....................................................3 Position Switch (lockable) ........ 3 Position Switch (lockable)

Voltage Regulation..................................................+/- 1% .......................................... +/-1%

Voltages A vailable 1Ø.............................................120, 139, 208, 220, 240, 277 ......120, 139, 208, 220, 240, 277

Voltages A vailable 3Ø.............................................208, 220, 440, 480 ...................... 208, 220, 440, 480

lbs (kg) ........................5826 (2643) ................................. 6568 (2979)

Trailer

Number of Axles .....................................................2................................................... 2

Capacity - Axle Rating lbs (kg) ..............................6000 (2722) .................................6000 (2722)

Tire Size in..............................................................16................................................. 16

Brakes.....................................................................Surge ........................................... Surge

Hitch - Standard......................................................3" Ring......................................... 3" Ring

Maximum Tire Pressure psi ....................................75................................................. 75

Page 11

SPECIFICATIONS

Specifications are subject to change without notice.

MAGNUM MODEL MMG 180 MMG 180 Super Start (SS) Engine

Make/Brand.............................................................John Deere .................................. John Deere

Model ......................................................................PE6068HF275 .............................PE6068HF275

Horsepower - prime hp (kW) ..................................228 (170) ..................................... 228 (170)

Horsepower - standby hp (kW) ..............................250 (187) ..................................... 250 (187)

Operating Speed rpm .............................................1800............................................. 1800

Displacement in

Cylinders - qty .........................................................6................................................... 6

Fuel Consumption - 100% prime gph (Lph)...........11.0 (41.6) ................................... 11.0 (41.6)

Battery Type............................................................Group 31...................................... Group 31

Battery Voltage (Quantity per Unit).........................12V (1)......................................... 12V (1)

Battery Rating .........................................................1000 CCA .................................... 1000 CCA

Generator

Make/Brand.............................................................Marathon Electric ........................ Marathon Electric

Model ......................................................................431PSL6202................................ 432PSL6210

Type, Insulation .......................................................Brushless, H ................................Brushless, H

(L) ...............................................415 (6.8) ...................................... 415 (6.8)

Generator Set (Engine/Generator)

3Ø - Standby kW (kVA) ..........................................155 (194) ..................................... 167 (209)

Amps - 3Ø St andby 480V (208V) A ........................233 (538) ..................................... 251 (580)

3Ø - Prime kW (kV A ) ..............................................145 (181) .....................................152 (190)

Amps - 3Ø Prime 480V (208V) A............................218 (502) ..................................... 229 (527)

1Ø - Standby kW (kVA) ..........................................125 (125) ..................................... 163 (163)

Amps - 1Ø St andby - 240V A..................................521............................................... 679

1Ø - Prime kW (kV A ) ..............................................120 (120) .....................................150 (150)

Amps - 1Ø Prime - 240V A......................................500............................................... 625

Frequency Hz..........................................................60................................................. 60

Power Factor...........................................................1 (1Ø), 0.8 (3Ø) ...........................1 (1Ø), 0.8 (3Ø)

Sound dB(A) 23 ft @ prime ...................................68................................................. 68

Weights

Dry Weight, Skid Mounted

Operating Weight, Skid Mounted lbs (kg) ..............8890 (4032) ................................. 9355 (4243)

Dry Weight, Trailer Mounted* lbs (kg) ....................8240 (3738) .................................8705 (3949)

Operating Weight, Trailer Mounted* lbs (kg)..........10830 (4912) ............................... 11295 (5123)

*Weights reflect units equipped with standard trailer only. Consult factory for custom trailer weights.

Capacities

Fuel Tank Volume gal (L) .......................................342 (1295) ...................................342 (1295)

Usable Fuel Volume gal (L)....................................313 (1185) ................................... 313 (1185)

Coolant (incl. engine) qt (L)....................................42.0 (39.7) ................................... 42.0 (39.7)

Oil (incl. filter) qt (L)................................................33.0 (31.2) ................................... 33.0 (31.2)

Maximum Run Time hrs .........................................28................................................. 28

AC Distribution

Circuit Breaker Size ................................................700............................................... 700

Voltage Selection....................................................3 Position Switch (lockable) ........ 3 Position Switch (lockable)

Voltage Regulation..................................................+/- 1% .......................................... +/-1%

Voltages A vailable 1Ø.............................................120, 139, 208, 220, 240, 277 ......120, 139, 208, 220, 240, 277

Voltages A vailable 3Ø.............................................208, 220, 440, 480 ...................... 208, 220, 440, 480

lbs (kg) ........................6300 (2858) ................................. 6765 (3069)

Trailer

Number of Axles .....................................................2................................................... 2

Capacity - Axle Rating lbs (kg) ..............................6000 (2722) .................................6000 (2722)

Tire Size in..............................................................16................................................. 16

Brakes.....................................................................Surge ........................................... Surge

Hitch - Standard......................................................3" Ring......................................... 3" Ring

Maximum Tire Pressure psi ....................................75................................................. 75

Page 12

SPECIFICATIONS

Specifications are subject to change without notice.

MAGNUM MODEL MMG 230 MMG 230 Super Start (SS) Engine

Make/Brand.............................................................John Deere .................................. John Deere

Model ......................................................................PE6068HF475 .............................PE6068HF475

Horsepower - prime hp (kW) ..................................286 (213) ..................................... 286 (213)

Horsepower - standby hp (kW) ..............................314 (234) ..................................... 314 (234)

Operating Speed rpm .............................................1800............................................. 1800

Displacement in

Cylinders - qty .........................................................6................................................... 6

Fuel Consumption - 100% prime gph (Lph)...........13.3 (50.3) ...................................13.3 (50.3)

Battery Type............................................................Group 31...................................... Group 31

Battery Voltage (Quantity per Unit).........................12V (1)......................................... 12V (1)

Battery Rating .........................................................1000 CCA ....................................1000 CCA

Generator

Make/Brand.............................................................Marathon Electric ........................ Marathon Electric

Model ......................................................................431PSL6206................................ 433PSL6216

Type, Insulation .......................................................Brushless, H ................................Brushless, H

(L) ...............................................415 (6.8) ...................................... 415 (6.8)

Generator Set (Engine/Generator)

3Ø - Standby kW (kVA) ..........................................203 (254) ..................................... 208 (260)

Amps - 3Ø St andby 480V (208V) A ........................306 (705) ..................................... 313 (722)

3Ø - Prime kW (kV A ) ..............................................186 (232) .....................................189 (236)

Amps - 3Ø Prime 480V (208V) A............................279 (644) ..................................... 284 (655)

1Ø - Standby kW (kVA) ..........................................N/A............................................... N/A

Amps - 1Ø St andby - 240V A..................................N/A............................................... N/A

1Ø - Prime kW (kV A ) ..............................................N/A............................................... N/A

Amps - 1Ø Prime - 240V A......................................N/A............................................... N/A

Frequency Hz..........................................................60................................................. 60

Power Factor...........................................................0.8 (3Ø) ....................................... 0.8 (3Ø)

Sound dB(A) 23 ft @ prime ...................................68................................................. 68

Weights

Dry Weight, Skid Mounted

Operating Weight, Skid Mounted lbs (kg) ..............9100 (4128) ................................. 9920 (4500)

Dry Weight, Trailer Mounted* lbs (kg) ....................8450 (3833) .................................9270 (4205)

Operating Weight, Trailer Mounted* lbs (kg)..........11040 (5008) ............................... 11860 (5380)

*Weights reflect units equipped with standard trailer only. Consult factory for custom trailer weights.

Capacities

Fuel Tank Volume gal (L) .......................................342 (1295) ...................................342 (1295)

Usable Fuel Volume gal (L)....................................313 (1 185) ...................................313 (1185)

Coolant (incl. engine) qt (L)....................................50.0 (47.3) ................................... 50.0 (47.3)

Oil (incl. filter) qt (L)................................................33.0 (31.2) ................................... 33.0 (31.2)

Maximum Run Time hrs .........................................24................................................. 24

AC Distribution

Circuit Breaker Size ................................................800............................................... 800

Voltage Selection....................................................Link/Reconnect Board ................. Link/Reconnect Board

Voltage Regulation..................................................+/- 1% .......................................... +/-1%

Voltages A vailable 1Ø.............................................N/A............................................... N/A

Voltages A vailable 3Ø.............................................208, 480 ...................................... 208, 480

lbs (kg) ........................6510 (2953) ................................. 7330 (3325)

Trailer

Number of Axles .....................................................2................................................... 2

Capacity - Axle Rating lbs (kg) ..............................7000 (3175) .................................7000 (3175)

Tire Size in..............................................................16................................................. 16

Brakes.....................................................................Surge ........................................... Surge

Hitch - Standard......................................................3" Ring......................................... 3" Ring

Maximum Tire Pressure psi ....................................75................................................. 75

Page 13

UNIT DIMENSIONS

Specifications are subject to change without notice.

Dimensions (L x W x H) MMG 125, 155 MMG 180, 230

Skid Mounted in (m) ............................. 132 x 50 x 73 (3.35 x 1.27 x 1.85) .........132 x 50 x 77 (3.35 x 1.27 x 1.96)

Trailer Mounted in (m) .......................... 210 x 86 x 90 (5.33 x 2.18 x 2.29) .........210 x 86 x 93 (5.33 x 2.18 x 2.36)

Page 14

SERVICE LOCATIONS

Page 15

MAIN CONTROL PANEL FEA TURES

1. DOCUMENT HOLDER

2. AIR FILTER METER: This gauge shows the condition of the air filter when the engine is running.

3. MAGNUM DIGITAL CONTROLLER (MDC): See pages 16 - 17 for additional information.

4. AUXILIARY LIGHT SWITCHES: These switches operate the optional control p anel and interior lights.

5. CIRCUIT BREAKERS FOR 120V GFCI CONVENIENCE OUTLETS, 20A (2)

6. CIRCUIT BREAKERS FOR 120/240V CONVENIENCE OUTLETS, 50A (3)

7. 120/240V TWIST-LOCK CONVENIENCE OUTLETS (3): These outlet s are used for connecting additional loads or equipment to the generator.

8. CONNECTION FOR BA TTER Y CHARGER (OPTIONAL): Allows for 120VAC input to power battery charger.

9. CONNECTION FOR ENGINE BLOCK HEA TER (OPTIONAL): Allows for 120VAC input to power the engine block heater.

10. 120V GFCI DUPLEX CONVENIENCE OUTLETS: Outlets for additional equipment that may require Ground Fault Interrupt (GFCI) protection.

11. REMOTE ST ART TERMINAL BLOCK: Used to connect the generator to a dry-cont act closure switch for remote starting of the generator .

12. OUTPUT GROUND CONNECTION: Ground lug for attaching the generator to a good earthen ground.

13. CONNECTION TERMINAL LUGS: External loads are wired to these lugs.

14. DOOR SAFETY SWITCHES: 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.

15. MAIN CIRCUIT BREAKER FOR CONNECTION LUGS: The MMG 125 has a 450A breaker, the 155 a 600A breaker, the 180 a 700A breaker and the 230 has an 800A breaker .

Page 16

MAGNUM DIGIT AL CONTROLLER (MDC)

The Magnum Digital Controller (MDC) is an enhanced digital generator controller used to start, stop and monitor the operation of the generator and the engine. The controller constantly monitors vital generator and engine functions for a number of pre-programmed alarm and fault conditions. When a fault condition occurs, the engine will shut down automatically and the Liquid Crystal Display (LCD) window will display the fault that caused the shutdown; to resume operation the fault condition must be resolved. The controller has the ability to provide the display readout in English and Sp anish; other languages are available. A screen print out of the display screen is also available. This controller also records a “History” of the unit’s performance which may be viewed at any time and will not be removed or lost when the controller is powered down.

MAN AUT

Ready PF 0.00 RPM 0

The MDC panel consists of five sections, including: the “CONTROL ON” / “CONTROL OFF” Toggle Switch and Fine Volt age Adjustment Screw; the “OPERATION” keypad; the LCD window; the “DIAGNOSTICS” keypad; and the “ST ATUS” Light Emitting Diodes (LED’s). The following is a brief summary of the operation of each section of the control panel:

1. The “CONTROL ON” / “CONTROL OFF” Toggle Switch and Fine Voltage Adjustment Screw

• Control On/Off Toggle Switch This toggle switch powers-up the control panel and the controller .

• Fine Volt age Adjustment Screw This screw may be adjusted to set the generator output voltage after the voltage selector switch has been changed from one phase to another. This adjustment must be accomplished within 45 seconds of st artup so that the unit does not experience a shut down alarm for “SENSING”.

2. The “OPERA TION” Keypad

• “ENGINE ST ART” Button The Power Screen Display must be in the “MAN” mode in the upper left corner of the LCD window and the “Ready/Manual” LED lit in the “Status” portion of the controller. Press the green “ENGINE START” button to start the unit.

• “ENGINE STOP” Button Press the red “ENGINE STOP” button to shut down the unit and start the “S top Value” timer.

• “MANUAL W” Button Press this button to change from the Automatic (Remote) st arting mode to Manual st arting mode.

• “AUTO

X” Button

Press this button to change from Manual starting mode to Automatic (remote) st arting mode.

Page 17

• “ALARM CANCEL” Button When an alarm is activated, either visually or audibly , press this button to silence or cancel the alarm.

• “FAULT RESET” Button Press this button to clear the fault from the LCD window after the fault has been corrected. Press “FAULT RESET” and “ENTER” to clear the John Deere ECU Alarm List Codes.

3. The Liquid Crystal Display (LCD)

• This window will toggle between the Generator Display Screen and the Engine Display Screen upon startup of the unit. By viewing these screens, the operator will be able to monitor both the engine and generator status while the unit is running.

4. The “DIAGNOSTICS” Keypad

•“S” Scroll-Up Button Press this button to scroll-up within the LCD window.

•“T” Scroll-Down Button Press this button to scroll-down within the LCD window.

• “P AGE SELECT” Button Pressing this button will select the next display screen.

• “ENTER” Button Pressing this button will place you inside the particular display to review the generators preprogrammed setpoints or parameters.

5. The “STATUS” Light Emitting Diodes (LED’s)

• These 6 LED’s will illuminate to display the current operational status of the generator;

- Alarm/Fault: Indicates active or inactive alarms, but not reset shutdown alarms.

- Warning: Indicates an active or inactive alarm, or a warning alarm that has not been reset

- Ready/Manual: Indicates the controller is ready to start and in the manual mode.

- Ready/Auto: Indicates the unit is in the “AUTO” mode ready for the remote start signal.

- Running: Indicates the unit is running.

- Supplying Load: Indicates a load is being applied to the generator.

GENERA T OR MONITORING

Generator information is shown on the Liquid Crystal Display (LCD) window in a toggling manner with the Engine information after the first 60 seconds of operation, then every five seconds thereafter. The generator display screen will show frequency , line to neutral voltage, line to line volt age and amperage.

Note: When loading the generator , it is import ant to observe the amperage to determine the load balance on each line of the generator. Minor load unbalances, usually 5% or less, will not cause any particular problems. Every effort should be made to distribute the load equally between all lines.

• Hertz: Displays output frequency .

• Generator Output V oltage: Line to Neutral display, single phase (1Ø).

• Generator Output V oltage: Line to Line display, 3 phase (3Ø).

• Amps: Displays the AC output amperage produced by the generator.

Page 18

ENGINE MONITORING

Engine information is shown on the Liquid Crystal Display (LCD) window in a toggling manner with the Generator information after the first 60 seconds of operation and then every 5 seconds thereafter. The engine display screen will show oil pressure, engine coolant temperature, fuel level and battery voltage.

• Oil Press: Displays engine oil pressure. The display registers oil pressure between 0-100 psi.

Normal operating pressure is between 35-80 psi.

• Eng Temp: Displays the temperature of the engine’s coolant. If the coolant temperature exceeds

the Maximum Water Temperature of 230° F the engine will automatically shut down. Zero “0” will be displayed until a minimum temperature of 100° F is reached.

• Fuel Level: Displays the relative fuel level in the fuel tank in percent (50% = 1/2 tank, 75% = 3/4

tank, etc.). If the fuel level drops below a programmed low fuel point – usually at 15%, a low fuel warning and optional audio alarm will be activated. If the fuel level drops below the programmed low fuel limit, usually at 5%, the engine will automatically shut down.(Note: The MLG 25 does not display fuel level).

• Vbat: Displays the engine battery voltage. A normal reading is 13-14V on 12 volt systems and

24-26 on 24 volt systems, (with the engine running).

Additional information may be viewed while the unit is in “MANUAL” or “AUTO” mode. By pressing the “Page Select” button, the operator will select one of the following screens; “Running” screen, “Password” screen, or “History” screen. In each of these page selections the operator may press the “S” or “T” buttons on the “DIAGNOSTICS” keypad to display additional information as follows:

• “Running” screen:

The operator may press the “S” or “T” buttons on the “DIAGNOSTICS” keypad to display the “Alarm List” screen, “ECU Alarm List” screen, “Run Hours” screen, “ECU V alues” screen, Engine display screen and Generator display screen.

• “Password” screen:

The operator may press the “S” or “T” buttons on the “DIAGNOSTICS” keypad to

move the “>” cursor up or down a list of text.

• “History” screen:

The operator may press the “S” or “T” buttons on the “DIAGNOSTICS” keypad to move the “>” cursor up or down a list of the latest alarm or shutdown codes. Pressing the “Enter” button at a particular selection will allow the operator to scroll to the right in the LCD window to view the generator operating parameters at the time of the alarm or shutdown.

Page 19

The history of alarms or codes of the unit are saved in the digital controller. The most

CONTROL

OFF

VOLTAGE

ADJUSTMENT

RHEOSTAT

recent alarm or code is the first to be listed, with the time/date of the alarm or code at the bottom of the screen. The controller stores up to 118 codes. When full, the controller will automatically remove the oldest file. These codes will not be lost when the control power toggle switch is powered off.

FINE VOL TAGE ADJUSTMENT

Upon start-up of the generator, the “Running” screen of the Magnum Digit al Controller (MDC) will display “SENSING” and will countdown from 45 seconds to “0” Zero. This is a safety feature of the controller to protect the generator from over or under voltage upon start-up.

“SENSING” is a 45 second time delay and count down process before the MDC records the generator nominal output voltage. This nominal generator voltage is then compared to the current set point voltage of the voltage selector switch. If the nominal voltage recorded by the controller is greater than or lower than the current set point voltage of the voltage selector switch setting by 10% or more, the controller will shut the generator down automatically . The display will read: Wrn VG1 or 2 or 3 Under/Over and/or Sd Vg1 or 2 or 3 Under/Over. This means the controller warned (“Wrn”) or even shut down (“Sd”) the unit due to an output voltage irregularity .

The output voltage of the generator may be adjusted after the generator is running by use of the fine voltage adjustment screw. The adjusting screw is located directly below the control On/Of f toggle switch on the control panel. This screw turns a rheostat that will provide an increase (“+”) or a decrease (“-”) in the generator output voltage as displayed on the Power Display Screen on the control panel. When making this adjustment, if the voltage is increased or decreased too fast or too slow , the unit will automatically shut down. This adjustment needs to be made within the 45 second delay and countdown to “0” Zero period.

To adjust the output voltage, check the output voltage on the Liquid Crystal Display (LCD) window labeled Gen freq & Hz. Look at the L1N voltage or the L12 voltage on the display. The generator nominal output voltage should be within 10% of the voltage rating on the voltage selector switch.

To adjust the output voltage loosen the lock nut at the base of the screw and turn the screw in the desired direction until the required voltage shown on the LCD window matches the stated voltage on the voltage selector switch.

Note: Each time the voltage selector switch is changed from one setting to another, an adjustment will need to be made to the fine voltage using this adjustment screw.

For Example: With the voltage selector switch set to “208/120V” 3 Phase position, the voltage displayed

on the Gen freq & Hz screen must be within ± 10 % of the 208/120 position (188-228 V Line to Line / 108-132 V Line to Neutral).

If the voltage is not set within 10% of the applied voltage or the voltage is not reset within the 45 second delay period, the generator will shut down automatically and the display will read Wn VG1 or 2 or 3 Under/Over and/or Sd Vg1 or 2 or 3 Under/Over.

Page 20

GENERA T OR START UP

Before starting the generator , carefully read over the pre-st art check list. Make sure that all of the items are checked before trying to start the generator . This check list applies to both manual and remote st arting of the generator.

PRE- START CHECK LIST

 Make sure the control ON/OFF toggle switch is in the OFF “O” position.  Make sure that the circuit breakers (main and convenience) are switched OFF “O”.  Check that the generator is properly grounded to a good earthen ground per any local and NEC

regulations.

 Check all electrical connections at the connection lugs. Are they wired correctly?  Are the connection lugs tight?  Check the voltage selector switch or link board and make sure that it is set to the desired voltage.  Is the voltage selector switch locked?  Is the generator sitting level?  Thoroughly check for any water inside the unit, on or near the generator. Dry the unit before starting.  Check oil, coolant and fuel levels and engine battery connections.  Check engine fan belt tension and condition.  Check engine fan belt guard.  Check engine exhaust system for loose or rusted components.  Check radiator and surrounding shroud for debris.  Are any of the generator covers loose or missing?  Are all preventative maintenance procedures up to date?  Check that the battery disconnect switch is on, if equipped.

MANUAL STARTING OF THE GENERAT OR

1. Move the control ON/OFF toggle switch to the “CONTROL ON / I” position.

2. The Liquid Crystal Display (LCD) window will quickly display system information, all Light Emitting

Diodes (LED’s) will flash.

3. The LCD window will indicate MANUAL mode and Ready. The Ready/Manual LED will be lit. Note:

The unit must be in the “MAN” Mode with the Ready/Manual LED lit to start the unit.

Page 21

4. Press the green “ENGINE ST AR T” button. The Prest art (Preheat) screen will be displayed (if

equipped) and a countdown will begin from 20 seconds to 0.

5. The Starting screen will be displayed. The engine will crank and st art running.

6. The Running screen will display . Note: It may t ake a few seconds for the engine to run smoothly and

reach its governed operating speed. The 45 second “SENSING” time delay will start to count down.

7. The LCD window will then toggle from the Running screen to the Generator Display Screen and then

to the Engine Display Screen.

8. If the engine does not start after the first cranking attempt, the engine will pause for 15 seconds to

allow the starter to cool. The LCD window will show “PAUSE”. The engine will make two more attempts to start for a total of three crank cycles.

9. Should the engine not start and run within 3 starting cycles, the LCD window will show “SD S tart fail”.

The starting sequence may be repeated after the starter has had a minimum of two minutes to cool. Press the “FAULT RESET” button to clear the controller. To start the unit, press the green “ENGINE ST ART” button. Note: The engine controller may skip the preheat engine steps on some of the larger

models.

Page 22

10. Once the engine starts it will immediately begin speeding up to a constant 1800 rpm. On units with

isochronous engine governing, the engine may hunt or change speeds until operating temperature is reached. After a few minutes of operation, the engine will be warmed up and the LCD window will show engine and generator operating parameters. Temperature will be shown as “0” until the engine temperature is approximately 100° F.

11. Once the generator is at normal operating temperature, check the generator for excessive noise or

vibration and any coolant, oil or fuel leaks before applying any loads.

12. Check that the AC output voltage is correct. The output voltage can be fine adjusted by using the fine

voltage adjustment screw (rheostat), as described on page 19.

13. Check that the frequency (Hz) is correct. With no loads connected to the generator, the frequency

should read approximately 60-62 Hz, depending on the type of engine governing used.

14. If all wiring connections have been made correctly, switch the main circuit breaker to the “ON / I”

position and then add any loads attached to the convenience outlets 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 OF THE GENERAT OR

The “AUTO” button is used when the generator is started from a location other than the control panel and by using a dry-contact closure remote start switch (transfer switch). “AUTO” (remote start) is the normal setting when the generator is being used as a standby power supply. Before putting the generator in the “AUTO” mode, review the Pre-Start Check List and Manual Starting of the Generator sections beginning on page 20. Also follow all safety warnings and information on isolating the generator with a transfer switch if the unit is to be used as a standby power supply, as described on pages 35 and 36. Then continue with the steps described below:

1. Perform a manual start of the generator 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” button, the Liquid Crystal Display (LCD) window should highlight “AUTO” in the upper left corner. Attach a jumper wire (minimum 16 gauge) across the two terminals on the remote start terminal block. This applies a ground to the Magnum Digital Controller (MDC) to close the starting circuit contacts. The engine should crank, st art and run.

3. Remove the jumper wire from the remote start terminal block and the engine will stop. Reconnect any

necessary wires from the remote start switch (transfer switch) to the remote start terminal block.

4. Confirm unit is in “AUTO” mode. The LCD window should have “AUT” highlighted in the upper left

corner.

5. Close (set to “ON / I”) the main circuit breaker.

6. Secure the generator by closing and locking all access doors.

7. The generator is now ready for remote starting.

SHUTTING DOWN THE GENERATOR

Check with personnel using power supplied by the generator and let them know that the power is going to be turned off. Make sure the power shutdown 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 (turn to OFF / “O”) all circuit breakers.

2. Let the engine run for approximately five minutes to allow it to cool down.

3. Push the red “ENGINE STOP” button. Pressing “Engine Stop” will result in the generator going into

the shutdown cycle and starting a 15 second shutdown timer called “Stop Value”. If the unit does not shutdown within 15 seconds a “Stop Fail” alarm will be displayed on the Liquid Cryst al Display (LCD) window.

4. Move the “CONTROL ON / I” toggle switch to the “CONTROL OFF / O” position.

Page 23

MAGNUM DIGIT AL CONTROLLER (MDC) INFORMATION DISPLAYS, FUNCTIONS AND

No. Engine State Machine Description

1 AfterCool Engine aftercooling, Cooling Pump output is closed.

2 Cooling The generator is cooling before stop.

3 Cranking Engine is cranking.

4 EmergMan Emergency Manual gen-set operation.

5 Init Autotest during controller power on.

6 Loaded

The generator is running at nominal speed and GCB OPEN/CLOSE is closed.

7 Not Ready The generator is not ready to start.

8 Pause Pause between start attempts.

9 Prestart Prestart sequence in process, Prestart output is closed.

10 Ready The generator is ready to run.

11 Running The generator is running at nominal speed.

12 Shutdown Shut-down alarm is activated.

13 Starting Starting speed is reached and the

Idle timer

is running.

14 Stop Stop

No. Electrical State Machine Description

1 StabilTO Stabilization Timeout

No. Type Description

1 Sensor fail (FLS)

Sensor fail is detected when measured value is 6% out of the selected characteristic. Sensor fail indicated by ##### symbol instead measured value.

2 Warning (WRN) When warning comes up, see list of possible alarms.

3 Shut down (SD)

When the shut-down alarm comes up the Magnum Digital Controller opens outputs GCB CLOSE/OPEN, FUEL, SOLENOID, STARTER AND PRESTART to stop the engine immediately.

RESET

The Magnum Digital Controller (MDC) constantly monitors vital generator and engine functions for a number of operation, alarm and fault conditions. When a fault condition occurs, the engine will shut down automatically and the Liquid Crystal Display (LCD) window will show the fault that has caused the shut down. To resume operation, the fault condition must be resolved. To reset the controller and resume operation, press the “FAULT RESET” button.

MAGNUM DIGIT AL CONTROLLER (MDC) – GENERATOR OPERA TIONAL STA TUS

The Magnum Digital Controller (MDC) displays the operational status of the generator using the following codes:

MAGNUM DIGIT AL CONTROLLER (MDC) - ALARM MANAGEMENT

The Magnum Digital Controller (MDC) is capable of displaying the following alarms:

Page 24

MAGNUM DIGITAL CONTROLLER (MDC) - LIST OF POSSIBLE ALARMS/DESCRIPTIONS

No.

Events

Specification

Protection

Type

Information

on Binary

Output

Available

Description

1 AnInIOM Sd SD YES

Shutdown alarm configurable on the input of IG-IOM/IGS-PTM.

2 AnInIOM Wrn WRN YES

Warning alarm configurable on the input of IG-IOM/IGS-PTM.

3 Battery Flat SD YES

If the controller switches off during starting sequence due to bad battery condition it doesn't try to start again and activates this protection.

4 Binary Input Configurable YES

Configurable Warning/Shutdown alarms on the inputs of IL-NT.

5 ChrgAlternFail WRN YES

Failure of the alternator for charging the battery.

6 EmergencyStop SD NO

If the input

Emergency stop

is opened shutdown is immediately

activated.

7 Engine Temp Sd SD NO

Water temperature is greater than

Sd Water temp

setpoint.

8 Engine Temp Wrn WRN YES

Water temperature is greater than

Wrn Water temp

setpoint.

9 Fgen <, > SD YES

The generator frequency is out of limits given by

Gen >f

and

Gen <f

setpoints.

10 Fuel Level Sd SD YES

Fuel level is smaller than

Sd Fuel Level

setpoint.

11 Fuel Level Wrn WRN YES

Fuel level is smaller than

Wrn Fuel Leve

l setpoint.

12 GCB fail SD NO

Failure of the generator circuit breaker.

13 Igen unbl SD NO

The generator current is unbalanced.

14 Low BackupBatt WRN NO

RTC backup battery is flat.

15 Oil Press Sd SD NO

Oil pressure is smaller than

Sd Oil press

setpoint.

16 Oil Press Wrn WRN YES

Oil pressure is smaller than

Wrn Oil press

setpoint.

17 Overload SD YES

The load is greater than the value given by

Overload

setpoint.

18 Overspeed SD YES

The protection comes active if the speed is greater than

Overspeed

setpoint.

19 ParamFail NONE NO

Wrong checksum of parameters. Happens typically after downloading new firmware or changing of the parameter. The controller stays in INIT mode. Check all parameters write at least one new parameter.

20 PickupFault SD NO

Failure of the magnetic pick-up sensor for speed measurement.

21 Sd IOM fail SD NO

Shutdown alarm in case of lost connection to IG-IOM/IGS-PTM module.

22 SprinklActive WRN NO

The protection is active if the output

Sprinkler

is closed.

23 Start failed SD YES

Gen-set start failed

24 Stop fail SD YES

Gen-set stop failed.

25 Ubat WRN YES

Battery voltage is out of limits given by

Batt overvolt

and

Batt

undervolt

setpoints.

26 Underspeed SD YES

During starting of the engine when the RPM reaches the value of

Starting RPM

setpoint the starter is switched off and the

speed of the engine can drop under

Start RPM

again. Then the Underspeed protection becomes active. Protection evaluation starts 5 sec

27 Vgen <, > SD YES

The generator voltage is out of limits given by

Gen <V

and

Gen >V

setpoints.

Shut down and warning fault conditions and the displayed message are described in the following table:

Page 25

1 SPN:100 EngOil Press

2 SPN:102 Boost Press

3 SPN:105 Intake Temp

4 SPN:110 EngCool Temp

5 SPN:175 EngOil Temp

6 SPN:629 Controller #1

7 SPN:636 PositionSensor

8 SPN:637 TimingSensor

9 SPN:651 InjectorCyl#1

10 SPN:652 InjectorCyl#2

11 SPN:653 InjectorCyl#3

12 SPN:654 InjectorCyl#4

13 SPN:655 InjectorCyl#5

14 SPN:656 InjectorCyl#6

15 SPN:677 EngStartRelay

16 SPN:1485 ECU MainRelay

Following ECU messages are displayed with the description:

28 Vgen unbal SD NO

The generator voltage is unbalanced more than the value of

Volt unbal

setpoint.

29 Wrn ECU Alarm WRN NO

ECU alarm list is not empty.

30 Wrn RA15 fail WRN NO

Warning alarm in case of lost connection to IGL-RA15 module.

31 WrnServiceTime WRN NO

The period for servicing is set by the

NextServTime

setpoint. The protection comes active if the running hours of the engine reach this value.

JOHN DEERE ECU INFORMATION DISPLAYS AND FUNCTIONS

This unit has a John Deere Electronic Engine Control Unit (ECU) which regulates the engine speed (RPM) and constantly monitors vital engine functions for a number of operation, alarm and fault conditions. When an operation, alarm or fault condition occurs, the Liquid Crystal Display (LCD) window will alert the operator either visually or audibly . In addition to the “Alarm List”, there is an “ECU Alarm List” which will list any faults specified by the John Deere ECU.

Press the “S” Scroll-Up button (on the diagnostic keypad) to view the “ECU Alarm List”. This will allow the operator to view a description of the fault, along with the diagnostic trouble codes located at the bottom of the display (see FIGURE 1). To further identify a fault by using these codes, refer to the John Deere Operators Manual supplied with the unit. To resume operation, the fault condition must be resolved and the code cleared from the display .

Diagnostic messages are read and displayed in the ECU Alarm List. The Suspect Parameter Number (SPN), Failure Mode Identifier (FMI) and Occurrence Counter (OC) are shown together with a description if possible. One SPN /FMI describes one fail information. If FMI is equal to 0 or 1, WRN is displayed in the ECU Alarm list. For any other FMI value FLS is displayed. Detailed SPM/FMI may been seen in SAE HS-1939 Publication, or refer to engine manufacturers ECU error codes list.

Page 26

MAGNUM DIGIT AL CONTROLLER (MDC) – HIST ORY

No.

Record Structure

Abbreviation

Historical value

1 AIM1 IG-IOM, IGS-PTM Analog input 1 value (when configured IG-IOM, IGS-PTM)

2 AIM2 IG-IOM, IGS-PTM Analog input 2 value (when configured IG-IOM, IGS-PTM)

3 AIM3 IG-IOM, IGS-PTM Analog input 3 value (when configured IG-IOM, IGS-PTM)

4 AIM4 IG-IOM, IGS-PTM Analog input 4 value (when configured IG-IOM, IGS-PTM)

5 BIM IG-IOM, IGS-PTM Binary inputs (when configured IG-IOM, IGS-PTM)

6 BIN Binary inputs IL-NT

7 BOM IG-IOM, IGS-PTM Binary outputs (when configured IG-IOM, IGS-PTM)

8 BOUT Binary inputs IL-NT

9 Date Date of historical event in format DD/MM/YY

10 EngT IL-NT Analog input 2 value (default Water temperature)

11 FC ECU alarm FailureCode

12 FLvl IL-NT Analog input 3 value (default Fuel level)

13 FMI ECUalarm Failure Mode Identifier

14 Gfrg Generator frequency

15 Ig1 Generator current L1

16 Ig2 Generator current L2

17 Ig3 Generator current L3

18 LChr Character of the load

19 Num Number of historical event

20 OilP IL-NT Analog input 1 value (default Oil pressure)

21 PF Generator PF

22 Pwr Generator active power

23 Reason Event specification

24 RPM Engine Speed

25 Time Time of historical event in format HH:MM:SS

26 Ubat Battery voltage

27 Vg1 Generator voltage L1

28 Vg2 Generator voltage L2

29 Vg3 Generator voltage L3

The Magnum Digital Controller (MDC) controller stores a record of each important event into the history file of the controller. The history file seats 118 records. When the history file is full, the oldest records are removed.

ADJUSTING THE DISPLAY BACK LIGHTING

The backlighting on the Liquid Crystal Display (LCD) window may be adjusted brighter or darker by the operator whenever the Magnum Digital Controller (MDC) is powered up.

1. Press and hold “Enter” and press “S” or “T” on the Diagnostics keypad to increase or decrease the display contrast as needed.

2. Release the “Enter” button and the “S” or “T”buttons when the desired backlighting is attained.

Note: Anytime an “*” is displayed on the LCD, the text or set point cannot be changed with out the use of a password. Contact Magnum Products Technical Support for assistance.

Page 27

RESETTING OF THE “TIME TO SERVICE” REMINDER

The Magnum Digital Controller (MDC) will display the message “ WrnServiceTime” when the unit is due for maintenance or service. The maintenance or service interval is set at 250 hours of engine running time. Once the unit has been serviced, the “ServiceTime” reminder needs to be reset to the 250 hour interval. The following procedure demonstrates how to reset the running hours to 250:

1. With the unit shut down, power up the controller with the “Control On/Off” Toggle Switch. The initialization screen will be displayed. The controller will toggle automatically to the “Ready” Display screen.

2. Press the “S” button. The “Alarm List” display screen will appear. The next screen will display lines of text; starting with the word “Password”, then “Basic Settings”, “Engine Params”, “Engine Protect” etc. The top line has a “> “ cursor before the word ‘Password”.

3. Press the “T” button to move the “> “cursor down to the “Engine Protect” line of text.

4. Press Enter. “NextServTime” will appear at the top of the display screen on the left side, with the current service time hour setting (250) one line below on the right side

5. Press Enter. The current run time in hours will now appear on the left side of the display screen, directly under “NextServTime”

6. Press the “S” button and reset the current run time hour setting to 250. If you overshoot the 250 time interval use the “T” button to get back to the 250 time interval.

7. Press “Enter” to save the current run time hour setting.

8. Move the “CONTROL ON / I” toggle switch to the “CONTROL OFF / O” position.

TROUBLESHOOTING AUTOMATIC SHUTDOWN CONDITIONS

LOW FUEL LEVEL SHUTDOWN

1. Check the fuel level on the Liquid Crystal Display (LCD) window.

2. Check for leaks in the fuel tank. The fuel tank should not run dry under normal circumstances. The engine controller will shut the engine down when there is 5% of fuel remaining in the tank. This is done to keep the fuel lines from running dry .

3. If the fuel level is good and no leaks are found, check the fuel level sender and the connecting wiring for damage. To check for continuity between the sender and the engine controller, remove the bolts from the control panel and open the panel like a door . Consult the appropriate DC wiring diagram in this manual for the proper path between the engine controller and the fuel level sender.

LOW OIL PRESSURE SHUTDOWN

1. Check the level of the engine oil with the dipstick. The engine controller will shut the engine down when the oil pressure is less than 20 psi. Add oil if required.

2. Visually inspect the engine for oil leaks.

3. If the oil level is good, restart the unit and verify the loss of oil pressure. Shut the engine down immediately if the oil pressure value does not read 5 PSI within five (5) seconds.

4. Check the oil pressure sender on the engine block and the connecting wiring for damage. To check for continuity between the sender and the engine controller, remove the bolts from the control p anel and open the panel like a door. Consult the appropriate DC wiring diagram in this manual for the proper p ath between the engine controller and the pressure sender.

5. If the oil level, pressure sender and wiring are good, the oil loss may be caused by engine failure. Consult the ENGINE OPERA TION AND MAINTENANCE MANUAL for additional information on excessive oil consumption.

LOW COOLANT LEVEL SHUTDOWN

1. Allow the engine to cool.

2. Check the coolant level in the radiator. To access the radiator cap, you must remove the access panel from the top of the enclosure directly above the radiator. Add coolant until it is 3/4” below the filler neck. Secure the radiator cap back into its original position.

3. Inspect coolant hoses, engine block and water pump for visible leaks.

Page 28

HIGH COOLANT TEMPERATURE SHUTDOWN

1. Check the coolant level in the overflow jug.

2. Restart the engine and read the coolant temperature to verify High Coolant Temperature Shutdown. Stop the engine immediately if the coolant temperature is 230°F or more.

3. Allow the engine to cool. Add coolant to the overflow jug if it is low and then check the level of coolant in the radiator. To access the radiator cap, you must remove the access panel from the top of the enclosure directly above the radiator. Add coolant until it is 3/4” below the filler neck. Secure the radiator cap back into its original position.

4. Check the radiator shroud and ducting for blockage and remove any foreign matter.

5. Inspect coolant hoses, engine block and water pump for visible leaks.

6. Check the tension of the serpentine drive belt for the water pump.

7. Check the coolant temperature sender on the engine block and the connecting wiring for damage. To check for continuity between the sender and the engine controller, remove the bolt s from the control panel and open the panel like a door. Consult the appropriate DC wiring diagram in this manual for the proper path between the engine controller and the temperature sender .

8. If the sender and wiring are good and no other problems are found, remove the load on the generator and restart the engine. Observe the coolant temperature and shut the engine down immediately if it starts to overheat. Consult the ENGINE OPERA TION AND MAINTENANCE MANUAL for additional information on engine overheating.

OVERCRANK SHUTDOWN

1. Check the fuel level in tank.

2. Check for proper operation of the fuel pump.

3. Check air filter for blockage.

4. If the engine will not start, consult the ENGINE OPERA TION AND MAINTENANCE MANUAL for additional information on troubleshooting starting problems.

OVERSPEED OR UNDERSPEED SHUTDOWN

1. Disconnect all loads and restart the generator. Read the frequency (Hz) on the LCD display. With no loads on the generator, the frequency should read 60.0 Hz.

2. If the frequency is above or below 60.0 Hz, the engine speed will have to be adjusted. See the engine manual for throttle adjustments on mechanical governed units and see the electronic governor manual for electronically controlled units.

Page 29

GENERATOR OUTPUT CONNECTION LUGS

The generator is equipped with connection lugs behind the lug door next to the customer convenience outlets. The lugs provide connection points for attachment of external loads to the generator. A large decal on the inside of the connection lug door details the proper connections for selected voltages.

WARNING

It is HIGHLY RECOMMENDED that only a trained and licensed electrician perform any

wiring and related connections to the generator. Inst allation should be in compliance with the

NA TIONAL ELECTRIC CODE (NEC) as well as any local or st ate guidelines as required by law.

Failure to follow proper installation requirements may result in equipment or property damage,

personal injury or death.

WARNING

Before any connections are made to the generator, make sure that the main circuit breaker and

the engine start switch are in the OFF “O” position and that the negative (-) battery cable is disconnected. Potentially lethal voltages may be present at the generator connection lugs.

DANGER

IMPROPER OR INCORRECT CONNECTIONS TO A BUILDINGS ELECTRICAL SYSTEM CAN CAUSE

POTENTIALLY LETHAL VOLTAGE TO BACKFEED ONTO UTILITY LINES. THIS MAY RESULT IN

INJURY OR ELECTROCUTION TO UTILITY WORKERS NEARBY. MAKE SURE THE GENERATOR IS

SUPPLYING POWER TO AN ISOLATED OBJECT OR BUILDING THAT IS NOT CONNECTED TO ANY

UTILITY LINES.

Connections to the lugs should be made by running the power cables up through the slots in the bottom of the rubber shield at the base of the box and not directly to the lugs. Use a hex-wrench to tighten the cable connections. The connection lug door is equipped with safety interlock switches that will trip the main circuit breaker and disable the voltage regulator , dropping the generator output to residual voltage, if the door is opened while the unit is operating.

WARNING

NEVER attempt to disable or modify the lug door safety switches!

A ground connection is located next to the connection lugs. The unit MUST HAVE this ground lug connected to a good earthen ground for proper operating safety . The ground connection SHOULD BE IN COMPLIANCE WITH

THE NA TIONAL ELECTRIC CODE (NEC) AS WELL AS ANY ST ATE OR LOCAL GUIDELINES OR CODES.

Page 30

VOLTAGE SELECTOR SWITCH (MMG 125-155-180)

The voltage selector switch is located on a panel attached to the generator behind the door located next to the fuel tank filler . The selector switch is a three position switch that mechanically changes the connections between the generator output leads and the connection lugs on the main control panel. V oltage ranges are selected by rot ating the handle on the switch to the desired voltage.

NOTICE

NEVER attempt to change the voltage selector switch while the engine is running!

This will cause severe arcing and damage to the switch and generator windings.

480/277V 3-PHASE

208/120V 3-PHASE

240/120V 1-PHASE

208 120

480 277

208 120

T10

T11

T12

L-N

L-L

L1 - L2 = 480V L1 - N = 277V L2 - L3 = 480V L2 - N = 277V L3 - L1 = 480V L3 - N = 277V

N =

L1 - L2 = 208V L1 - N = 120V L2 - L3 = 208V L2 - N = 120V L3 - L1 = 208V L3 - N = 120V

480 277

208 120

240 120

T12

240 120

T10

T11

L-N

T12

240V

T11

L-L

T10

T4 T1

N =

L1 - L3 = 240V L2 - N = ------L1 - N = 120V L3 - N = 120V

120V120V

The voltage selector switch is equipped with a locking mechanism. Once the proper voltage has been selected, push the red latch on the inside of the switch handle up and insert a padlock through the handle. By locking the handle in place you will prevent unauthorized personnel from changing the switch settings.

Note: When the voltage selector switch is in position for 480/277V 3Ø, voltage at the two GFCI duplex convenience outlets is 139 Volts and the volt age at the three twist-lock outlet s is 240/139 Volts. When the voltage selector switch is in position for 208/120V 3Ø, voltage at the three twist-lock outlets and the two GFCI duplex

convenience outlets is 208/120 Volts.

Page 31

4-POSITION VOLTAGE SELECTOR SWITCH (OPTIONAL)

The optional four position voltage selector switch is located on a panel attached to the generator behind the door located next to the fuel tank filler . The voltage selector is a four position switch that mechanically changes the connections between the generator output leads and the connection lugs on the main control panel. V oltage ranges are selected by rotating the handle on the switch to the desired voltage.

NOTICE

NEVER attempt to change the voltage selector switch while the engine is running!

This will cause severe arcing and damage to the switch and generator windings.

Note: (The following applies to units without a convenience outlet buck transformer:) When the voltage selector switch is in position for 277/480V 3Ø, voltage at the two GFCI duplex convenience outlets is 139 Volt s and the voltage at the three twist-lock outlets is 139/240 Volt s. When the volt age selector switch is in position for 120/208V 3Ø, voltage at the two GFCI duplex convenience outlets is 120 Volt s and the volt age at the three twist-lock outlet s is 120/208 Volts. When the voltage selector switch is in position for 120/240 3Ø (DELT A), volt age at the two GFCI duplex convenience outlets is 120 Volts and the THREE TWIST LOCK OUTLETS SHOULD NOT BE USED. When the voltage selector switch is in position for 120/240V 1Ø, voltage at the two GFCI duplex convenience outlets is 120 Volts and the volt age at the three twist-lock outlet s is 120/240 V olt s.

Page 32

CHANGING OUTPUT VOL TAGE (MMG 230 ONLY)

The output voltage can be changed by moving the shorting (link) board in the generator reconnect box. The reconnect box is located on the top of the generator. Before attempting to change the output volt age, shut the generator down and make sure that the main circuit breaker and the control power switch are in the off “O” position.

WARNING

Never attempt to change the voltage while the engine is running.

Lethal voltage may be present at the connection lugs on the reconnect board.

To receive 480/277 V 3Ø voltage at the connection lugs, the shorting (link) board must be attached in the lower position as shown in the illustration. For 208/120 3Ø voltage, the shorting (link) board must be in the upper position as shown in the illustration. If the board needs to be changed from one setting to the other, remove all of the 1/2” nuts that hold the shorting (link) board down and move it to the new position. Replace all of the hardware and tighten it to 25 ft-lbs. of torque.

Reinstall the reconnect box door and start the generator by following the instructions in the GENERATOR STAR TUP section, beginning on page 20.

REMOVE ALL

1/2” NUTS

T10

T11

T12

L-N

L-L

LINK BOARD ATTACHED IN

480 VOLT 3Ø POSITION

T10

L-L

T11

L-N

LINK BOARD ATTACHED IN

208 VOLT 3Ø POSITION

T12

Page 33

EMERGENCY STOP SWITCH

The generator is equipped with one emergency stop switch, located on the right rear corner of the unit next to the control door. The switch is clearly labeled “EMERGENCY STOP” and is red in color. The switch can be accessed and activated with all doors closed and locked.

Activate the emergency stop switch by pushing the red button in until it locks down. This will trip the main circuit breaker which will open the contact disconnecting the load to the

connection lugs. This will also open the fuel circuit, shutting down the engine. The Emergency Stop fault will be displayed on the control panel.

The switch will remain closed until it is pulled out.

NOTICE

Use the EMERGENCY STOP switch only when the generator must be shut down immediately.

For any other shut down, follow the detailed procedure on page 22.

MAIN CIRCUIT BREAKER

The main circuit breaker is located on the main control panel. When the breaker is in the off “O” position, power is interrupted between the customer connection lugs and the generator. Once the connections have been made to the connection lugs and the generator has been started and allowed to reach normal operating temperature, the breaker may be switched to the on “I” position. Use the breaker handle extension supplied with this unit to apply additional leverage to the switch.

The main circuit breaker will be tripped, disconnecting power to the connection lugs, if any of the following items occur while the unit is running:

ON/I

1. Overload of the generator circuits to the connection lugs.

2. The door covering the customer connection lugs is opened.

3. If the emergency stop switch is activated.

4. If the door to the reconnect box (link board) is removed.

Make sure that any problems that cause the main circuit breaker to trip are corrected

OFF/O

before returning the switch to the on “I” position.

WARNING

The main circuit breaker interrupts power to the customer connection lugs only.

The customer convenience outlets have power even if the main circuit breaker is in the

OFF “O” position.

To disconnect power to the convenience outlets, use the individual circuit

breakers located near each outlet.

VOL T AGE REGULA TION

The electronic voltage regulator controls the output of the generator by regulating the current into the exciter field. The regulator has three screwdriver adjustable potentiometers that may be adjusted for voltage, stability and under frequency (U/F). The voltage regulator on your unit is adjusted before shipment from the factory. Contact Magnum Products LLC for additional information before attempting to adjust the voltage regulator .

Page 34

CUSTOMER CONVENIENCE OUTLETS

The generator is equipped with five convenience outlets. The large outlets are 240/120 VAC twist-lock receptacles rated at 50 A each. The smaller outlets are 120 V AC duplex recept acles rated at 20 A each with ground fault interrupt (GFCI) protection. These receptacles are not routed through the main circuit breaker. Each receptacle has its own circuit breaker , located directly above or next to the outlet. Each breaker is sized to the maximum

rating of the corresponding outlet.

20A CIRCUIT

BREAKERS

120V DUPLEX

CONVENIENCE OUTLETS

50A CIRCUIT

BREAKERS

120/240V TWIST LOCK

CONVENIENCE OUTLETS

NOTICE

Power to the outlets is available any time the generator is running, EVEN IF THE MAIN

CIRCUIT BREAKER IS OFF “O”. MAKE SURE THA T ANY EQUIPMENT CONNECTED TO

THE CONVENIENCE OUTLETS IS TURNED OFF BEFORE TURNING THE BREAKERS ON.

Make sure that the voltage selector switch is in the proper position and that the output voltage is correct for the equipment that is connected to the outlet s. Improper voltage

may cause equipment damage or malfunction.

Note: When the voltage selector switch is in position for 480/277V 3Ø, voltage at the two GFCI duplex convenience outlets is 139 Volt s and the voltage at the three twist-lock outlet s is 240/139 Volts. When the voltage selector switch is in position for 208/120V 3Ø, voltage at the three twist-lock outlets and the two GFCI outlets is 208/120 volts.

DERA TING FOR ALTITUDE

All generator sets are subject to derating for altitude and temperature; this will reduce the available power for operation of tools and accessories connected to the auxiliary outlets. T ypical reductions in performance are 2-4% for every 1000 ft. (305 meters) of elevation and 1% per 10º F (3-5º C) increase in ambient air temperature over 72º F (22.2º C).

Page 35

REMOTE ST ART TERMINAL BLOCK

The remote start terminal block is located just under the two 120V duplex convenience outlets. It provides a connection for installation of a remote start switch which will allow the generator to be started by a remote dry-contact closure switch.

Before pressing the “AUTO” button (or moving the toggle switch to the REMOTE START position on analog units), verify that the contacts on any remote switch linked to the generator are OPEN. If the contacts on a remote switch are closed, the generator will crank and start when AUTO (or REMOTE ST AR T) is selected. Attach the switch leads to the two unused terminals on the generators remote start block. For additional information on starting the generator , see GENERA TOR START UP on p age 20.

When the generator is used as a standby power supply , it must be equipped with a transfer

REMOTE

START

SWITCH

TERMINALS

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.

DANGER

FAILURE TO ISOLATE THE GENERATOR FROM THE NORMAL POWER UTILITY CAN

CAUSE POTENTIALLY LETHAL VOLTAGE TO BACKFEED INTO THE UTILITY LINES. THIS

MAY RESULT IN INJUR Y OR ELECTROCUTION OF UTILITY WORKERS NEARBY. MAKE

SURE THA T THE GENERATOR IS ISOLA TED BY A TRANSFER SWITCH FROM ANY LOCAL

UTILITY LINES. THIS ALSO APPLIES IF THE GENERATOR IS BEING USED AS A BACK UP

TO SOME OTHER TYPE OF POWER SUPPLY.

INCOMING

UTILITY POWER

UTILITY

METER

POWER FROM

GENERATOR

EMERGENCY

DISTRIBUTION PANEL

(GENERATOR POWER)

MAIN DISTRIBUTION

PANE L

(UTILITY POWER)

TRANSFER

SWITCH

WHITE = INCOMING UTILITY POWER

GRAY = NORMAL UTILITY POWER CIRCUIT

BLACK = EMERGENCY GENERATOR POWER CIRCUIT

Page 36

Installation of a transfer switch or other type of remote starting device is the responsibility of the generator user . Installation of such devices must be performed by following all directions supplied by the manufacturer of the switch. If attaching generator to a power supply normally serviced by a utility company, notify the utility company and check local and state regulations. Familiarize yourself with all instructions and warning labels supplied with the switch.

WARNING

It is strongly recommended that ONLY a licensed electrician perform any wiring and any related

connections to the generator. Installation should be in compliance of the National Electric Code as

well as any state or local codes or regulations. Failure to follow these procedures could result in property damage, personal injury or death. Before any connections are attempted, make sure the main circuit breaker and the engine start switch are in the OFF “O” position and that the negative

(-) battery cable has been disconnected from the engine starting battery.

NOTICE

When using the generator as a stand by 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.

ENGINE AND GENERATOR 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 even routine service (oil/filter changes, cleaning, etc.) unless all electrical components are shut down. When servicing this equipment always follow the instructions listed below.

• Before servicing this machine, make sure the engine start switch is turned to the OFF “O” position.

• The circuit breakers are open (OFF, “O”).

• The emergency stop switch is activated (pushed in).

• The negative (-) terminal on battery is disconnected.

• Attach a “DO NOT START” sign to the control panel. This will notify everyone that the unit is being serviced

and will reduce the chance of someone inadvertently trying to start the unit.

• If the unit is connected to a remote start or transfer switch, make sure the remote switch is also off and tagged.

• Never wash the unit with a high pressure hose or with any kind of power washer.

• Never wash the engine block or fuel tank with a power washer or steam cleaner. Water may enter the

cabinet and collect in the generator windings or other electrical parts, causing damage.

• If the unit is stored outside, check for water inside the cabinet and generator and dry the unit thoroughly before starting.

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.

The engine is 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 speeds and/or light load or if makeup oil is required, a longer break in period may be needed. Consult the engine OPERA TION AND MAINTENANCE MANUAL for a full description of necessary procedures on the addition of break-in oil and extension of the break-in period. Use the schedule table on the

following page as a guide for regular maintenance intervals.

Page 37

DAIL Y MAINTENANCE CHECKS

Check the engine oil level daily before starting engine. DO NOT start the generator if the oil level is below the ADD mark on the dipstick. The normal operating level for the engine oil is anywhere in the crosshatch pattern between the FULL and ADD markings. Add oil to the engine only if the level is below the ADD mark on the bottom of the crosshatch pattern. DO NOT OVERFILL the crankcase. Consult the engine OPERATION AND MAINTENANCE MANUAL for the proper grade of oil, including special operating conditions such as a change in season or climate.

Check the coolant level daily . The coolant is checked by visually inspecting the level in the coolant overflow jug, located near the radiator. The normal operating level is anywhere between the FULL and ADD markings on the overflow jug, with the optimum level noted as “NORMAL RANGE”. Coolant may be added directly to the overflow jug WHEN THE ENGINE IS STOPPED AND COMPLETELY COOL. Consult the engine OPERATION AND MAINTENANCE MANUAL for coolant recommendations and proper mixture.

Check the condition of the air filter by viewing the level of 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. H20).

* Replace primary air cleaner when restriction indicator shows a vacuum of 25 in. H2O.

** Change the oil and oil filter after the first 100 hours, then every 250 hours.

*** If engine manufacturer’s recommended coolant is used, the flushing interval may be extended.

See engine OPERA TION AND MAINTENANCE MANUAL.

LIFTING THE GENERA T OR

A large central lif ting eye is located on the top of the generator and the eye is connected to a central lifting frame inside the unit. Attach a sling or hook directly to the lif ting eye only if the devices are in good condition and the equipment being used to raise the unit has sufficient capacity. Approximate weights can be found on pages 9-12. Always remain aware of others around you when moving or lifting the generator. Keep the cabinet doors closed and locked.

CENTRAL LIFT EYE

Page 38

TOWING THE TRAILER

1. Use the jack to raise or lower the trailer onto the hitch of the towing vehicle. Lock the hitch coupling and attach the safety chains or cables to the vehicle. Release the jack locking pin and rotate the jack into the travel position. Make sure the locking pin snaps into place.

2. Connect any trailer wiring to the tow vehicle. Check for proper operation of the stop and signal lights.

3. Make sure all doors are closed and secure.

4. Check for proper inflation of the trailer tires. Maximum tire pressures can be found on pages 9-12.

5. Check the wheel lugs. Tighten or replace any that are loose or missing. If a tire has been removed for axle service or replaced, tighten the lugs in the order shown to the following specifications:

A. Start all lug nuts by hand. B. First pass tighten to 20-25 Ft-Lbs (27-33 Nm). C. Second pass tighten to 50-60 Ft-Lbs (67-81 Nm). D. Third pass tighten to 90-120 Ft-Lbs (122-162 Nm).

After the first road use, re-torque the lug nuts in sequence.

6. Maximum recommended speed for highway towing is 45 m.p.h. Recommended off-road towing speed is not to exceed 10 m.p.h. or less depending on terrain.

5-Stud Sequence

6-Stud Sequence

8 -Stud Sequence

TRAILER WHEEL BEARINGS

Some trailers may be equipped with a grease zerk 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 zerk 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; more frequent lubrication may be required under extremely dusty or damp operating conditions.

Page 39

AC WIRING DIAGRAM, MMG125, MMG155, MMG180

BRKER

20A

120V

GFCI

RECPT

120V

GFCI

RECPT

GND

120V

20A

BRKER

GROUND

GRN/YEL

TO GEN FRAME

GRN/YEL

BRN

50A

RCPT.

240V

BLK

BREAKER

240V 50A

BLK

WIRES NOT USED IN

BUCK BOOST OPTION

240V

50A

BLK

BREAKER

240V 50A

BLK

(T7)

RCPT.

BLK

PAIR BLK

50A

240V

BLK

BREAKER

240V 50A

BLK

PAIR BLK

RCPT.

LT BLU

(T9)

LT BLU

(L0)

PAIR BLK

10 14

T6T8T10

GROUND

GENERATOR

T11T7T1

FRAME

F-

F+

T12

(3) JUMPER

12-17, 10-21

SWITCH 15-20,

WIRES ON PHASE

PLUG

21 PIN

RED

BLK

MECHANICAL LUGS

L2 L3

LUG DOOR

SAFETY SWITCH

BUCK BOOST OPTION

QTY 2 BRN

VOLTAGE

ADJUSTMENT

BRN/WHT

RED F+

BLK F-

F+

F-

WHT

(2.5K, 2 WATT)

4 AMP FUSE

BLK

BRN

50HZ

60HZ

ON REGULATOR

CT-3

CT-2CT-1

SHUNT 12VDC

MAIN

CIRCUIT

BREAKER

BRN/WHT

BLK

VOLTAGE

SENSING RELAY

RELAY

WHT

COM

RED

BUCK XFORMER

H1 H3 X4X2

WHT

BLK

X1 X3

WHT

SEE DC WIRING DIAGRAM FOR CT CONNECTIONS

BLK

SE350

VOLTAGE REGULATOR

Page 40

AC WIRING DIAGRAM, MMG230

FRAME

GROUND

120V

MECHANICAL LUGS

GFCI

RECPT

GND

L2 L3

120V

20A

BRKER

3/0

GRN/YEL 14GA

6 AWG

GRN/YEL 14GA

GRN/YEL 10GA

GROUND

TO GEN FRAME

SHUNT 12VDC

50A

240V

RCPT.

BLK

240V 50A

BREAKER

BLK 10GA

50A

240V

RCPT.

BLK

240V 50A

BREAKER

BLK 10GA

(T7)

50A

240V

BLK

240V 50A

BLK 10GA

PAIR BLK 6GA

RCPT.

BLK

BREAKER

LT BLU 10GA

BLK 10GA

(T9)

PAIR BLK 6GA

CT-3

CT-2CT-1

LT BLU 10GA

(L0)

PAIR BLK 6GA

LT BLU 10GA

QTY 3 BLK 3/0

T1T2T3T4T5

L2 L3

F-

T12

F+

T11

GENERATOR

T10

PLUG

21 PIN

RED

BLK

BOARD

RECONNECT

T8T7

T4 T6

T10, T11, T12

VOLTAGE

(2.5K, 2 WATT)

ADJUSTMENT

QTY 2 BRN 14

RELAY

WHT 10GA

WHT 14GA

800A

CIRCUIT

BREAKER

DOOR

208V SHORT

23-PIN

PLUG 1

BLK 14GA

VOLTAGE RELAY

TO 21 POS PLUG SEE DC PRINT

COM

RED 10GA

H1 H3 X4X2

BLK 10GA

BUCK XFORMER

BLK 10GA

X1 X3

WHT 10GA

RECONNECT

SAFETY SWITCH

480V SHORT

TO LUG DOOR SW SEE DC PRINT

SE350

VOLTAGE REGULATOR

BRN/WHT

BLK F+

BLK F-

F+

F-

WHT

4 AMP FUSE

BLK

BRN

50HZ

60HZ

ON REGULATOR

Page 41

DC WIRING DIAGRAM, MMG125, MMG155, MMG180

GN/YL

GND ON BOARD

LOCATION

RPM IN

RPM GND

LOCATION

AI1 (OIL)

AI2 (TEMP)

GTB

ORN

WT/VI

AI3 (FUEL)

GROUND TERMINAL BLOCK

YEL

12/B

BRN

PINPLUG LOCATION

GN/YL

LOCATION

SAFETY

SWITCH

LUG DOOR

MJB

STARTER

RELAY

RED

BLK

123 45 67 89

RED

B+

POWER

CONTROL

RED

RD/WT

ORN

BLK

C+

YEL

RD/WT

SWITCH

RD/BK

LOCATION

D+

RD/YL

BLK

RD/WT

C1 +12VDC

RD/YL

RD/BK

C2 +12VDC

BO1 START

RD/VI

BO3

BO2 FUEL

BO4

BO5

BO6

BO7

RED

RD/WT

ORN

GN/YL

GRY

BLK

GY/BK

WT/VI

ORN

BLK

SHLD

GY/OR

BI2

XTUVWMNP RSHJ KLC

REMOTE START

BLK

GY/BK

BI3

BI4

BI5

BLK

CONTACTS

ORN

BI6

RED

GRY

SHLD

GY/BK

WT/VI

RD/VI

BI7

RD/WT

ORN

GN/YL

GRY

DEUTSCH

GEN

LOW

21-PIN J

DEUTSCH

CAN-H

21-PIN V

21-PIN F

DEUTSCH

F+

F-

COOLANT

ALT. EXCITE

21-PIN U

DEUTSCH

CAN-SHLD

BLK

RED

F+

VOLTAGE

BLK

REGULATOR

F-

RD/VI

GRY

BI1

LOCATION

RED

BLK

15A

BLK

ORG

ORN

YEL

RED

BLK

678

GRN

WHT

SPLICE

WHT

SHUNT

L1 L2 L3

MAIN

BREAKER

ORN

YEL

BRN

WHT

L2L3N

2/B

BLK

GRN

BLK

GN/YL

ORN

SPLICE

YEL

GRN

BLK

CT-2

CT-1

CT-3

WHT

BR/WT

YL/WT

OR/WT

GRN

L3L2L1

COM

LOCATION

RED

12 V

BATTERY

OPTIONAL

DISCONNECT

BLK

NO NO

GEN FIELD

CAN-L

BLK

SWITCH

E-STOP

SWITCH

E-STOP

GROUND

FUEL

VIO

SHIELD

BLK

GRY

LOCATION

RED

GROUND TO

TO TANK

LEVEL

90208, ORG 7.25.08

MOTOR

STARTER

B+

RED

ALT

B+

ENGINE BLOCK

"RUN"

21-PIN G

DEUTSCH

Cut back and Tape

Shield not connected

COM

2 PIN PLUG (RPM)

BOTTOM

PLUG LOCATION

MDC CONTROLLER

BOTTOM

3 PIN PLUG (ANALOG INPUTS)

PLUG LOCATION

MAG REF

MAG IN

WATER IN

OIL IN

TOP

LARGE 4 PIN PLUG (GEN VOLTAGE)

PHASE A VOLTAGE

PHASE B VOLTAGE

PHASE C VOLTAGE

FUEL IN

NEUTRAL

TOP

4 PIN PLUG (GEN CURRENT)

PLUG LOCATION

PHASE GND

PHASE C CURRENT

PHASE B CURRENT

PHASE A CURRENT

RELAY BOARD

PLUG LOCATION PIN

BOTTOM

POWER + DC

POWER - DC

D+

BO1

3 PIN PLUG

BOTTOM

7 PIN PLUG (BINARY INPUTS)

PLUG LOCATION

OPEN

BO2

SRT

FUE

OPEN

LOW COOLANT OPTION

OPEN

E STOP

REMOTE START

PLUG LOCATION

LEFT SIDE

ECU H

ECU COM

ECU L

*NOT REQUIRED WITH JOHN DEERE ECU ENGINE

Page 42

DC WIRING DIAGRAM, MMG230

SAFETY

SWITCH

LUG DOOR

BLK

678

WHT

SPLICE

WHT

MAIN

GRN

SHUNT

BREAKER

2/B

BLK

GRN

BLK

YEL

BLK

CT-1

WHT

BR/WT

LOCATION

GN/YL

GND ON BOARD

LOCATION

RPM IN

RPM GND

LOCATION

AI1 (OIL)

AI2 (TEMP)

GTB

ORN

WT/VI

AI3 (FUEL)

GROUND TERMINAL BLOCK

YEL

12/B

GN/YL

BRN

PINPLUG LOCATION

LOCATION

L1 L2 L3

ORN

YEL

BRN

WHT

L2L3N

GN/YL

SPLICE

BLK

CT-2

WHT

YL/WT

ORN

BLK

CT-3

WHT

OR/WT

TO 3 POS LUG BLOCK T7 SEE DC PRINT

TO VOLTAGE REGULATOR 3 SEE DC PRINT

SAFETY

SWITCH

LUG DOOR

MJB

RED

BLK

15A

BLK

ORG

ORN

YEL

RED

GRN

COM

RED

RD/WT

ORN

123456789

BLK

RED

BLK

C+

YEL

RELAY

STARTER

B+

RED

BLK

RD/WT

POWER

SWITCH

CONTROL

R/BLK

RD/BK

SWITCH ONLY

TO PHASE SW

4 POS PHASE

SEE AC PRINT

LOCATION

D+

RD/YL

BLK

RD/WT

C1 +12VDC

RD/YL

RD/BK

C2 +12VDC

BO1 START

RD/VI

BO3

BO2 FUEL

BO4

BO5

BO6

BO7

GY/BK

WT/VI

GY/OR

BI2

XTUVWMNP R SHJKLC

GRY

GY/BK

BI3

BI4

BI5

RED

BLK

BRN

BLK

GRY

BR/WT

RED

BLK

GY/BK

WT/VI

ORN

RD/VI

BLK

GRY

SHLD

BLK

RD/WT

ORN

GN/YL

GRY

LOW

21-PIN J

DEUTSCH

21-PIN V

DEUTSCH

21-PIN F

DEUTSCH

CONTACTS

REMOTE START

F+

GEN

F-

GEN

COOLANT

ALT. EXCITE

CAN-H

DEUTSCH

CAN-SHLD

RECONNECT

GEN FIELD

BI6

RED

BLK

BRN

BLK

GRY

BR/WT

RD/WT

ORN

GN/YL

GRY

RED

F+

VOLTAGE

BLK

REGULATOR

F-

BLK

ORN

RD/VI

BLK

GRY

SHLD

GRY

BI1

LOCATION

12 V

BATTERY

OPTIONAL

DOOR SW

NO NO

CAN-L

21-PIN U

RED

BATTERY

DISCONNECT

BLK

VIO

BLK

GROUND TO

NO24NC

SWITCH

E-STOP

SWITCH

E-STOP

GROUND

FUEL

LEVEL

RED

MOTOR

STARTER

B+

RED

ALT

B+

ENGINE BLOCK

TO TANK

"RUN"

21-PIN G

DEUTSCH

SHIELD

BLK

GRY

Shield not connected

LOCATION

Cut back and Tape

COM

2 PIN PLUG (RPM)

BOTTOM

MDC CONTROLLER

PLUG LOCATION

BOTTOM

3 PIN PLUG (ANALOG INPUTS)

MAG IN

PLUG LOCATION

MAG REF

OIL IN

WATER IN

TOP

PHASE A VOLTAGE

LARGE 4 PIN PLUG (GEN VOLTAGE)

PHASE B VOLTAGE

FUEL IN

PHASE C VOLTAGE

NEUTRAL

4 PIN PLUG (GEN CURRENT)

PLUG LOCATION

TOP

PHASE A CURRENT

PHASE GND

PHASE C CURRENT

PHASE B CURRENT

RELAY BOARD

PLUG LOCATION PIN

BOTTOM

POWER + DC

D+

POWER - DC

BO1

3 PIN PLUG

OPEN

6 PIN PLUG (BINARY INPUTS)

PLUG LOCATION

BOTTOM

REMOTE START

LOW COOLANT OPTION

RECONNECT DOOR

OPEN

E STOP

PLUG LOCATION

LEFT SIDE

ECU H

ECU COM

ECU L

OPEN

FUE

SRT

BO2

*NOT REQUIRED WITH JOHN DEERE ECU ENGINE

Page 43

AC WIRING DIAGRAM, MMG125, MMG155, MMG180

For units equipped with an optional 4-position voltage selector switch.

GEN

BOX

FRAME

GROUND

F-

F+

120V

GFCI

MECHANICAL LUGS

RECPT

GND

L2 L3

LUG DOOR

SAFETY SWITCH

120V

GENERATOR

T10

T11

(3) JUMPER

WIRES (DASHED)

T12

BLK

10 14

ORN

TP3A

BRKER

20A

RCPT.

240V

50A

RCPT.

240V

BLK

20A

BRKER

GRN/YEL

6 AWG

GROUND

TO GEN FRAME

6GA

SHUNT 12VDC

CIRCUIT

BREAKER

BRN/WHT

BLK

BRN

240V 50A

BREAKER

BLK

BRN

WIRES NOT USED IN

BUCK BOOST OPTION

BLK

240V 50A

BREAKER

BLK

(T7)

RCPT.

240V

50A

BLK

240V 50A

BREAKER

BLK

(T9)

BLK

GRN

VOLT REGULATION

RELAY

LT BLU

BLK

(L0)

46 53

ORN

WHT/BR

YEL

CT-3

CT-2CT-1

"W" SEE DC

TO 21 PIN PLUG

RED

BRN

BRN/W

WHT

CT-3

YEL

BRN

10GA

ON PHASE SWITCH

TP3

TP3A

RED

X SEE DC

TO PLUG2 POS

CT-2

CT-1

PLUG

21 PIN

TP0

RED

BLK

ADJUSTMENT

(2.5K, 2 WATT)

VOLTAGE

BRN/WHT

BLK

BLK F-

BRN

WHT

BLK F+

F+

F-

SE350

VOLTAGE REGULATOR

4 AMP FUSE

50HZ

60HZ

ON REGULATOR

BLK

VOLTAGE RELAY

RELAY

WHT

COM

X2 X4H3H1

RED

BUCK XFORMER

BRN

BUCK BOOST OPTION

GN/YL

BR/WT

YL/WT

OR/WT

BLK

X3X1

WHT

INPUTS

GEN VOLTAGE

CT3

CT2

CT COMMON

COM

CT1

INPUTS

4 PIN PLUG 4 PIN PLUG

GENERATOR CURRENT

ELECTRONIC CONTROL BOARD

Page 44

AC WIRING DIAGRAM, MMG230

For units equipped with an optional 4-position voltage selector switch.

RELAY

VOLT REGULATION

GRN

3564

YEL

RED

BRN

BRN/W

T3T2T1T4T5

7011 19 32 8

1440

TIE POINT 1

120V

GFCI

RECPT

GND

120V

20A

BRKER

GRN/YEL 14GA

6 AWG

GRN/YEL 14GA

GRN/YEL 10GA

GROUND

TO GEN FRAME

50A

RCPT.

240V

BLK

BREAKER

240V 50A

BLK 10GA

240V

50A

BLK

BREAKER

240V 50A

BLK 10GA

(T7)

RCPT.

240V

PAIR BLK 6GA

50A

RCPT.

BLK

BREAKER

240V 50A

BLK 10GA

(T9)

PAIR BLK 6GA

LT BLU 10GA

(L0)

PAIR BLK 6GA

LT BLU 10GA

BLK

ORN

WHT/BR

GROUND

GENERATOR

FRAME

F-

F+

T12 T11 T10

PLUG

21 PIN

RED

BLK

1623

TIE POINT 2

MECHANICAL LUGS

SEE DC DIAGRAM

TO BREAKER SHUNT

L2 L3

NC NO

LUG DOOR

SAFETY SWITCH

QTY 2 BRN 14

3/0

CT-3

CT-2CT-1

3/0

SHUNT 12VDC

800A

CIRCUIT

BREAKER

X SEE DC

TO PLUG2 POS

(2.5K, 2 WATT)

VOLTAGE

ADJUSTMENT

BRN/WHT 14GA

BLK 14GA

VOLTAGE RELAY

RELAY

COM

BLK 10GA

SE350

VOLTAGE REGULATOR

BRN/WHT

RED F+

BLK F-

F+

F-

WHT

4 AMP FUSE

BLK

BRN

50HZ

60HZ

ON REGULATOR

RED 10GA

BUCK XFORMER

H1 H3 X4X2

WHT 10GA

WHT 14GA

X1 X3

WHT 10GA

Page 45

TRAILER LIGHTS WIRING DIAGRAM

Page 46

NOTES:

Page 47

SERVICE LOG

OIL GRADE AND TYPE: BRAND: COOLANT MIXTURE: BRAND:

Page 48

REV: J PART NO: 22070

10.20.08

Magnum MMG 125, MMG 180, MMG 155, MMG 230 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual