Magnum MMG150, MMG170, MMG235 Operating Manual

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Page 1

DIESEL GENERATOR

MMG150 • MMG170 • MMG235

OPERATING MANUAL

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 contai ned 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 States 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 Products LLC, or

can be found at www.m-p-llc.com. An engine operator’s 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

For technical or part s QUESTIONS, please contact Magnum Products’ Customer Support or

Technical Support team at 920-361-4442 or toll free at 1-800-926-9768. Please have your serial

number available.

To ORDER SERVICE PARTS, please contact the dealer from which you purchased the unit, or call

Magnum Products to locate a dealer in your area.

Supplemental information may be available for your unit ; when ordering p a rt s ALWAYS check for a supplement that applies to your unit. A supplement may have been provided with your un it and can

be found on the Magnum Products LLC website.

Engine Make:__________________________________________ Engine Serial Number:___________________________________ Engine Model Number: __________________________________ Generator Make: _______________________________________ Generator Model Number: ________________________________ Generator Serial Number: ________________________________ Unit Model Number:_____________________________________ Unit Serial Number: _____________________________________

CALIFORNIA PROPOSITION 65 WARNING: Diesel engine exhaust and some of its

constituents are known to the state of California to cause cancer, birth defects and

WARNING

other reproductive harm.

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TABLE 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

SPECIFICATIONS .....................................................................................................................................9

UNIT DIMENSIONS .................................................................................................................................12

SERVICE LOCATIONS ............................................................................................................................ 13

MAIN CONTROL PANEL FEATURES, STANDARD ............................................................................... 14

MAIN CONTROL PANEL FEATURES, WITH OPTIONAL CAM LOCKS ................................................ 16

MAGNUM DIGITAL CONTROLLER (MDC) ............................................................................................. 18

DIGITAL CONTROLLER FEATURES AND FUNCTIONS ....................................................................... 18

GENERATOR MONITORING ..................................................................................................................19

ENGINE MONITORING ...........................................................................................................................19

FINE VOLTAGE ADJUSTMENT .............................................................................................................21

PRE - START CHECK LIST ..................................................................................................................... 22

MANUAL STARTING OF THE GENERATOR .........................................................................................22

“AUTO” (REMOTE) STARTING OF THE GENERATOR ......................................................................... 24

SHUTTING DOWN THE GENERATOR ..................................................................................................24

MDC CONTROLLER INFORMATION DISPLAYS, FUNCTIONS AND RESET ...................................... 25

MAGNUM DIGITAL CONTROLLER (MDC) – GENERATOR OPERATIONAL STATUS ........................25

MAGNUM DIGITAL CONTROLLER (MDC) - ALARM MANAGEMENT ..................................................25

MAGNUM DIGITAL CONTROLLER (MDC)- LIST OF POSSIBLE ALARMS/DESCRIPTIONS ..............26

JOHN DEERE ECU INFORMATION DISPLAYS AND FUNCTIONS ...................................................... 27

MDC CONTROLLER (MDC) – HISTORY ................................................................................................28

ADJUSTING THE DISPLAY BACK LIGHTING ........................................................................................ 28

RESETTING OF THE “TIME TO SERVICE” REMINDER ........................................................................29

TROUBLESHOOTING AUTOMATIC SHUT DOWN CONDITIONS ........................................................29

GENERATOR OUTPUT CONNECTION LUGS ....................................................................................... 31

GENERATOR CAM LOCK CONNECTIONS (OPTIONAL) ......................................................................32

VOLTAGE SELECTOR SWITCH (MMG150 & MMG170 ONLY) ............................................................ 33

4-POSITION VOLTAGE SELECTOR SWITCH (OPTIONAL) .................................................................. 34

CHANGING OUTPUT VOLTAGE (MMG235 ONLY) ............................................................................... 35

EMERGENCY STOP SWITCH ................................................................................................................36

MAIN CIRCUIT BREAKER ......................................................................................................................36

VOLTAGE REGULATION .........................................................................................................................36

CUSTOMER CONVENIENCE OUTLETS ................................................................................................ 37

DERATING FOR ALTITUDE ....................................................................................................................37

REMOTE START TERMINAL BLOCK ..................................................................................................... 37

TRANSFER SWITCH ...............................................................................................................................38

ENGINE AND GENERATOR MAINTENANCE ........................................................................................ 39

DAILY WALK AROUND INSPECTION ....................................................................................................39

BELT TENSION ........................................................................................................................................39

ENGINE BREAK-IN REQUIREMENTS ...................................................................................................40

DAILY MAINTENANCE CHECKS ............................................................................................................ 40

LIFTING THE GENERATOR .................................................................................................................... 41

TOWING THE TRAILER ..........................................................................................................................41

TRAILER WHEEL BEARINGS .................................................................................................................41

AUXILIARY FUEL TANK OPTION ........................................................................................................... 42

FUEL TRANSFER PUMP OPTION .........................................................................................................42

CHECKING GENERATOR DRIVE PLATE TORQUE ............................................................................... 42

TRAILER WIRING DIAGRAM ..................................................................................................................43

ELECTRIC BRAKE WIRING HARNESS .................................................................................................44

AC WIRING DIAGRAM: MMG150-MMG170 ........................................................................................... 45

AC WIRING DIAGRAM: MMG150-MMG170 - 4-POSITION PHASE SWITCH .......................................46

AC WIRING DIAGRAM: MMG235 ........................................................................................................... 47

AC WIRING DIAGRAM: MMG235 - 4-POSITION PHASE SWITCH .......................................................48

DC WIRING DIAGRAM: MMG150-MMG170 ...........................................................................................49

DC WIRING DIAGRAM: MMG235 ...........................................................................................................50

SERVICE LOG .........................................................................................................................................51

Page

Page 4

SAFETY NOTES

DANGER

CAUTION

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.

INDICA TES A HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN

Indicates a hazardous situation which, if not avoided, could result in death or serious

Indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.

Indicates a hazardous situation which, if not avoided, may result in property or equipment

DEATH OR SERIOUS INJURY.

WARNING

injury.

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 unit on a combustible surface.

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

1. Noticeable change in engine speed.

2. Loss of electrical output.

3. Equipment connected to the generator overheats.

4. Sparking occurs.

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

6. Protective covers are loose or missing.

7. If the ambient air temperature is above 120° 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 unit when it was shipped from the factory.

• DO NOT run engine indoors or in an area with poor ventilation. Diesel engine exhaust contains carbon

monoxide, a deadly, odorless and colorless gas which, if inhaled, can cause nausea, fainting or death. Only use this unit outside and away from windows, doors and ventillation 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 engine is hot.

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

in excess of 85 DBA 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 lug nuts holding wheels are tight and that none are missing.

• Maximum recommended speed for highway towing is 45 mph. Recommended off-road towing speed is not to exceed 10 mph 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 Traffic 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 Products LLC.

To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-888-327-4236 (TTY:1-800-424-9153), go to http://www.safercar.gov; or write to:

Administrator NHTSA 1200 New Jersey Avenue S.E. Washington, DC 20590

You can also obtain other information about motor vehicle safety from http://www.safercar.gov.

Page 7

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

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

MODEL

SERIAL NUMBER 000000 kg lbs MADE IN USA

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

MAGNUM PRODUCTS LLC

BERLIN, WI 54923 USA

(800) 926-9768

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

Page 8

SAFETY SYMBOL SUMMARY

Hot surface(s) nearby.

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

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

Remove negative battery cable before performing any service on unit.

Stop engine before making connections.

Use clean diesel fuel only.

Unit electrical ground.

Hearing protection required while operating unit with doors open.

Anchor/tie down point.

Lift here only.

Asphyxiation hazard; Operate in well ventilated area.

Dangerous voltage may be present.

Never change switch position while engine is running.

Burn/scald hazard; pressurized steam.

Fan hazard; Keep body parts clear of this area.

Isolate generator to prevent electrocution hazard.

Belt/entanglement hazard; Keep body parts clear of this area.

Safety alert symbol; Used to alert you to potential personal injury hazards.

Stop engine before fueling.

Engine running.

This equipment has been supplied with numerous safety and operating decals. These decals provide important operating instructions and warn of dangers and hazards. Replace any missing or hard-to-read decals and use care when washing or cleaning the unit. Decal placement and part numbers can be found in the parts section or parts manual included with your unit. Below is a summary of the intended meanings for the symbols used on the decals.

Page 9

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 MMG150 MMG150 Super Start Engine

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

Model ............................................................................... PE6068HF285 ..............................PE6068HF285

Horsepower - prime hp (kW) ..........................................180 (134).......................................180 (134)

Horsepower - standby hp (kW) ....................................... 197 (147).......................................197 (147)

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 ............................................................................... 363PSL1661 .................................432PSL6210

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

Generator Set (Engine/Generator)

3Ø - Standby kW (kVA) ................................................... 127 (159).......................................131 (164)

Amps - 3Ø Standby 480V (208V) A ................................ 191 (441).......................................197 (455)

3Ø - Prime kW (kVA) ...................................................... 116 (145).......................................119 (149)

Amps - 3Ø Prime 480V (208V) A .................................... 174 (402).......................................179 (414)

1Ø - Standby kW (kVA) ................................................... 114 (114) .......................................128 (128)

Amps - 1Ø Standby - 240V A .......................................... 475 ................................................533

1Ø - Prime kW (kVA) ...................................................... 106 (106).......................................117 (117)

Amps - 1Ø Prime - 240V A ............................................. 442 ................................................488

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

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

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

Weights

Dry Weight, Skid Mounted lbs (kg) .................................5944 (2696)...................................6409 (2907)

Operating Weight, Skid Mounted lbs (kg) ...................... 8500 (3856)...................................8965 (4066)

Dry Weight, Trailer Mounted* lbs (kg) ............................ 7340 (3329)...................................7805 (3540)

Operating Weight, Trailer Mounted* lbs (kg) ..................9896 (4489)...................................10361 (4700)

*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) ........................................................ 31.5 (29.8).....................................31.5 (29.8)

Maximum Run Time hrs .................................................32 ..................................................32

AC Distribution

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

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

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

Voltages Available 1Ø...................................................... 120, 139, 208, 220, 240, 277 ........120, 139, 208, 220, 240, 277

Voltages Available 3Ø...................................................... 208, 220, 440, 480 ........................208, 220, 440, 480

Trailer

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

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

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

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

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

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

.3" Ring

Page 10

SPECIFICATIONS

MAGNUM MODEL MMG170 MMG170 Super Start Engine

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

Model ............................................................................... PE6068HF285 ..............................PE6068HF285

Horsepower - prime hp (kW) ..........................................216 (161).......................................216 (161)

Horsepower - standby hp (kW) ....................................... 237 (177).......................................237 (177)

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

Displacement in

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

Fuel Consumption - 100% prime gph (Lph) ................... 10.9 (41.3).....................................10.9 (41.3)

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 ............................................................................... 431PSL6306 .................................432PSL6210

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

Generator Set (Engine/Generator)

3Ø - Standby kW (kVA) ................................................... 150 (188).......................................158 (198)

Amps - 3Ø Standby 480V (208V) A ................................ 226 (522).......................................238 (550)

3Ø - Prime kW (kVA) ...................................................... 137 (171).......................................144 (180)

Amps - 3Ø Prime 480V (208V) A .................................... 206 (475).......................................217 (500)

1Ø - Standby kW (kVA) ................................................... 125 (125).......................................154 (154)

Amps - 1Ø Standby - 240V A .......................................... 521 ................................................642

1Ø - Prime kW (kVA) ...................................................... 120 (120).......................................142 (142)

Amps - 1Ø Prime - 240V A ............................................. 500 ................................................592

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

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

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

Weights

Dry Weight, Skid Mounted lbs (kg) .................................6139 (2785)...................................6604 (2996)

Operating Weight, Skid Mounted lbs (kg) ...................... 8567 (3886)...................................9032 (4097)

Dry Weight, Trailer Mounted* lbs (kg) ............................ 7535 (3418)...................................8000 (3629)

Operating Weight, Trailer Mounted* lbs (kg) ..................9963 (4519)...................................10428 (4730)

*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) ............................................ 31.5 (29.8).....................................31.5 (29.8)

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

Maximum Run Time hrs .................................................29 ..................................................29

AC Distribution

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

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

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

Voltages Available 1Ø...................................................... 120, 139, 208, 220, 240, 277 ........120, 139, 208, 220, 240, 277

Voltages Available 3Ø...................................................... 208, 220, 440, 480 ........................208, 220, 440, 480

Trailer

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

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

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

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

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

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

.3" Ring

Page 11

SPECIFICATIONS

MAGNUM MODEL MMG235 MMG235 Super Start Engine

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

Model ............................................................................... PE6068HF485 ..............................PE6068HF485

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

Horsepower - standby hp (kW) ....................................... 315 (235).......................................315 (235)

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

Displacement in

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

Fuel Consumption - 100% prime gph (Lph) ................... 15.2 (57.5).....................................15.2 (57.5)

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 ............................................................................... 431PSL6336 .................................433PSL6216

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

Generator Set (Engine/Generator)

3Ø - Standby kW (kVA) ................................................... 204 (255).......................................209 (261)

Amps - 3Ø Standby 480V (208V) A ................................ 307 (708).......................................251 (724)

3Ø - Prime kW (kVA) ...................................................... 186 (233).......................................190 (237)

Amps - 3Ø Prime 480V (208V) A .................................... 280 (647).......................................285 (658)

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

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

1Ø - Prime kW (kVA) ...................................................... 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)

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

Weights

Dry Weight, Skid Mounted lbs (kg) .................................6510 (2953)...................................7330 (3325)

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)

*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) ............................................ 38.0 (35.9).....................................38.0 (35.9)

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

Maximum Run Time hrs .................................................21 ..................................................21

AC Distribution

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

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

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

Voltages Available 1Ø...................................................... N/A ................................................N/A

Voltages Available 3Ø...................................................... 208, 480 ........................................208, 480

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 .........................................

Maximum Tire Pressure psi ............................................ 80 ..................................................80

.3" Ring

Page 12

UNIT DIMENSIONS

50”

132”

77”

86”

210”

93”

Dimensions (L x W x H)

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

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

Page 13

SERVICE LOCATIONS

Page 14

MAIN CONTROL PANEL FEATURES, STANDARD

891011

Page 15

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 18-19 for additional information.

4. AUXILIARY LIGHT SWITCHES: These switches operate the optional control panel 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 outlets are used for connecting additional loads

or equipment to the generator.

8. CONNECTION FOR BATTERY CHARGER (OPTIONAL): Allows for 120VAC input to power onboard battery

charger.

9. CONNECTION FOR ENGINE BLOCK HEATER (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-contact 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 150 has one 600A breaker, the MMG 170

a 700A breaker and the MMG 235 has an 800A breaker.

Page 16

MAIN CONTROL PANEL FEATURES, WITH OPTIONAL CAM LOCKS

ENGINE START

ENGINE STOP

CONTROL

OFF

CONTROL

AUT

MAN

0 kW 0

DIAGNOSTICS

Ready PF 0.00 RPM 0

PAGE

SELECT

ENTER

OPERATION

MANUAL AUTO

ALARM

CANCEL

ALARM/FAULT

READY/MANUAL READY/AUTO

RUNNING SUPPLYING LOAD

ENGINE START

CONTROL

ENGINE

FAULT

OFF

RESET

STOP

STATUS

WARNING

910

Page 17

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 18-19 for additional information.

4. AUXILIARY LIGHT SWITCHES: Operate optional control panel and interior lights.

5. CIRCUIT BREAKER FOR CAM LOCK CONNECTORS (OPTIONAL): Units equipped with one set of cam lock

receptacles (as shown) have one 450A breaker. Units equipped with two sets of cam lock receptacles have two 450A breakers.

6. CAM LOCK CONNECTORS (OPTIONAL): Series 16 Taper Nose 400A, 600V cam locks are connected here.

See page 32 for more information.

7. OUTPUT GROUND CONNECTION: (Green) Cam lock ground connection for attaching the generator to a good

earthen ground.

8. CONNECTION FOR BATTERY CHARGER (OPTIONAL): Allows for 120VAC input to power onboard battery

charger.

9. CONNECTION FOR ENGINE BLOCK HEATER (OPTIONAL): Allows for 120VAC input to power the engine

block heater.

10. 120/240V TWIST-LOCK CONVENIENCE OUTLETS (3): These outlets are used for connecting additional loads

or equipment to the generator.

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

starting of the generator.

12. 120V GFCI DUPLEX CONVENIENCE OUTLETS (2): Outlets for additional equipment that may require Ground

Fault Interrupt (GFCI) protection.

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

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

15. DOOR SAFETY SWITCHES: The connection lug door and cam lock door are equipped with safety interlock

switches that will trip the main circuit breaker and disable the voltage regulator if the doors are opened while the unit is operating.

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

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

18. MAIN CIRCUIT BREAKER FOR CONNECTION LUGS: The MMG 150 has one 600A breaker, the MMG 170

a 700A breaker and the MMG 235 has an 800A breaker.

Page 18

MAGNUM DIGITA L 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 shut down; to resume operation the fault condition must be resolved. The controller has the ability to provide the display readout in English and Spanish; 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.

The MDC panel consists of five sections, including: the “CONTROL ON/OFF” Toggle Switch and Fine Voltage Adjustment Screw; the “OPERATION” keypad; the LCD window; the “DIAGNOSTICS” keypad; and the “STATUS” Light Emitting Diodes (LED’s).

DIGITAL CONTROLLER FEATURES AND FUNCTIONS

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

• “CONTROL ON/OFF” T oggle Switch: This toggle switch powers-up the control panel and the controller.

• Fine V oltage Ad justment 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 within 45 seconds of start-up so that the unit does not experience a shut down alarm for “SENSING”.

2. The “OPERATION” Keypad

• “ENGINE START” Button: The Power Screen Display must be in the “MAN” mode in the upper left corner

of the LCD window display 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 “Stop

Value” timer.

• “MANUAL W” Button:Press this button to change from the Automatic (remote) starting mode to Manual

starting mode.

• “AUTO X” Button: Press this button to change from Manual starting mode to Automatic (remote) starting

mode.

be accomplished

Page 19

• “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.

• “PAGE 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

pre programmed setpoints or parameters.

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

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

○ Alarm/Fault: Indicates active or inactive alarms, but not reset shut down 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.

GENERATOR MONITORING

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

Note: When loading the generator, it is important to observe the amperage to determine the load ba lance on each line of the generator. Minor load unbalances, usually five percent or less, will not cause any particular problems. Every effort should be made to distribute the load equ ally be tween all lines.

• Hertz: Displays output frequency.

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

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

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

ENGINE MONITORING

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

Page 20

• 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 level of fuel in the tank by percentage (50% = 1/2 tank, 75% = 3/4 tank, etc.). If the

fuel level drops below a programmed low fuel point – usually at 15%, a low fuel warning and optional audio alarm will be activated. If the fuel level drops below the programmed low fuel limit, usually at five percent, the engine will automatically shut down.

• 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 Values” 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 recent alarm or shut down 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 shut down. The history of alarms or codes is saved in the digital controller. The most recent alarm or code is the first to be listed, with the time/date of the alarm or code at the bottom of the screen. The controller stores up to 118 codes. When full, the controller will automatically remove the oldest file. These codes will not be lost when the “CONTROL ON/OFF” toggle switch is powered off.

Page 21

FINE VOLTAGE ADJUSTMENT

Upon start-up of the generator, the “Running” screen of the Magnum Digital 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

VOLTAGE DJUSTMENT RHEOSTAT

CONTROL

OFF

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 shut down (“Sd”) the unit due to an output voltage irregularity.

The output voltage of the generator may be adjusted after the generator is running by using the fine voltage adjustment screw. The adjusting screw is located directly below the “CONTROL ON/OFF” toggle switch on the control panel. This screw turns a rheostat that will provide an increase (“+”) or a decrease (“-”) in the generator output voltage as displayed on the Power Display Screen on the control panel. 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.

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).

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.

Page 22

PRE - START CHECK LIST

DANGER

Before starting the generator, carefully read the pre-start 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 starting of the generator.

 Read and understand ALL safety sections at the beginning of this manual.

 Make sure the control ON/OFF toggle switch is in the OFF “O” position.  Make sure 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 and cam lock receptacles (if equipped). Are

they wired correctly? Are they tight?

 Check the voltage selector switch 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 GENERATOR

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

CARBON MONOXIDE: USING A GENERATOR INDOORS CAN KILL YOU IN MINUTES!

2. The Liquid Crystal Display (LCD) window will quickly display system information, all Light Emitting Diodes (LED’s) will flash.

3. The LCD window will indicate “MAN” (manual) mode and “Ready”. The Ready/Manual LED will be lit. Note: The

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

Page 23

4. Press the green “ENGINE START” button. The Prestart (Preheat) screen will be displayed (if equipped) and a countdown will begin from 20 seconds to 0.

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

6. The Running screen will display.

Note: It may take 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.

Page 24

9. Should the engine not start and run within three starting cycles, the LCD window will show “SD Start fail”. The starting sequence may be repeated after the starter has had a minimum of two minutes to cool. Press the “FAULT RESET” button to clear the controller. To start the unit, press the green “ENGINE START” button.

Note: The engine controller may skip the preheat engine steps on some of the larger models.

10. Once the engine starts it will immediately begin speeding up to a constant 1800 rpm. The engine may hunt or change speeds until operating speed is reached. After a few minutes of operation, the engine will be warmed up and the LCD window will show engine and generator operating parameters. Temperature will be shown as “0” until the engine temperature is approximately 100° F.

11. Check the generator for excessive noise or vibration and any coolant, oil or fuel leaks before applying any loads.

12. Check that the AC output voltage is correct. The output voltage can be fine adjusted by using the fine voltage adjustment screw (rheostat), as described on page 21.

13. Check that the frequency (Hz) is correct. With no loads connected to the generator, the frequency should read approximately 60 Hz, depending on the type of engine governing used.

14. If all wiring connections have been made correctly, switch the main circuit breaker to the “ON / I” position and then add any loads attached to the 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 GENERATOR

The “AUTO” button is used when the generator is started from a location other than the control panel and by using a 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 22. 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 (see page 38). 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, start and run.

3. Remove the jumper wire from the remote start terminal block and the engine will stop. Reconnect any necessary wires from the remote start switch (transfer switch) to the remote start terminal block.

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

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

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

7. The generator is now ready for remote starting.

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 shut down will not create any hazards by accidentally turning off equipment that needs to be kept on (pumps, compressors, lights, etc.).

1. Remove all loads from the generator by opening all circuit breakers (turn to OFF / “O”).

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

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

Page 25

MDC CONTROLLER INFORMATION DISPLAYS, FUNCTIONS AND RESET

No. Engine State Machine Description

1 AfterCool Engine aftercooling, Cooling Pump output is closed.

2 Cooling The unit 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 unit is running at nominal speed and GCB OPEN/CLOSE is closed.

7 Not Ready The unit is not ready to start.

8 Pause Pause between start attempts.

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

10 Ready The unit is ready to run.

11 Running The unit 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.

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.

The operation of the Magnum Digital Controller (MDC) is divided into the following sections:

MAGNUM DIGITAL CONTROLLER (MDC) – GENERATOR OPERATIONAL STATUS

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

MAGNUM DIGITAL CONTROLLER (MDC) - ALARM MANAG EM ENT

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

Page 26

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 IGIOM/IGS-PTM.

2 AnInIOM Wrn WRN YES

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

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 W rn 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.

Oil Press Sd (Shut Down)

SD NO

Oil pressure is smaller than

Sd Oil press

setpoint.

Oil Press Wrn (Warning)

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

IOM/IGS-PTM module.

22 SprinklActive WRN NO

The protecion 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.

28 Vgen unbal SD NO

The generator voltage is unbalanced more than the value of

Volt unbal

setpoint.

29 W rn ECU Alarm WRN NO ECU alarm list is not empty.

30 W rn RA15 fail WRN NO

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

31 W rnServiceTime WRN NO

The period for servicing is set by the

NextServTime

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

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

Page 27

JOHN DEERE ECU INFORMATION DISPLAYS AND FUNCTIONS

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:

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 failure. If FMI is equal to zero or one, “WRN” is displayed in the ECU Alarm list. For any other FMI value “FLS” is displayed. Detailed SPN*/FMI information may been found in the SAE HS-1939 Publication, or refer to engine manufacturers ECU error codes list.

*Note: The Suspect Parameter Number (SPN) is displayed as “FC” on the bottom left of the LCD window. See FIGURE 1.

Page 28

MDC CONTROLLER (MDC) – HISTORY

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 brightness on the Liquid Crystal Display (LCD) window may be adjusted by the operator whenever the Magnum Digital Controller (MDC) is powered up.

Note: Anytime an “*” is displayed on the LCD window, the text or set point cannot be changed without the use of a password. Contact Magnum Products Technical Support for assistance.

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

2. Release the “Enter” button when the desired brightness is attained.

Page 29

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 left of the display screen. The current service time hour setting (250) will be one line below it 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 pass 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 SHUT DOWN CONDITIONS

LOW FUEL LEVEL SHUT DOWN

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 five percent of fuel remaining in the tank. This is done to keep the fuel lines from running dry.

3. If the fuel level is good and no leaks are found, check the fuel level sender and the connecting wiring for damage. To check for continuity between the sender and the engine controller, remove the appropriate bolts from the control panel to access the inside of the control box. Consult the appropriate DC wiring diagram in the parts manual for the proper path between the engine controller and the fuel level sender.

LOW OIL PRESSURE SHUT DOWN

1. Check the level of the engine oil with the dipstick. The engine controller will shut the engine down when the oil pressure is less than 20 psi. 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 five (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 appropriate bolts from the control panel to access the inside of the control box. Consult the appropriate DC wiring diagram in the parts manual for the proper path 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 OPERATION AND MAINTENANCE MANUAL for additional information on excessive oil consumption.

LOW COOLANT LEVEL SHUT DOWN

1. Allow the engine to cool.

2. Check the coolant level in the radiator. To access the radiator cap, you must remove the access panel from the top of the enclosure directly above the radiator. Add coolant until it is 3/4” 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 30

HIGH COOLANT TEMPERATURE SHUT DOWN

1. Check the coolant level in the overflow jug.

2. Restart the engine and read the coolant temperature to verify High Coolant Temperature Shut down. Stop the engine immediately if the coolant temperature is 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 appropriate bolts from the control panel to access the inside of the control box. Consult the appropriate DC wiring diagram in the parts 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 OPERATION AND MAINTENANCE MANUAL for additional information on engine overheating.

OVERCRANK SHUT DOWN

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 OPERATION AND MAINTENANCE MANUAL for additional information on troubleshooting starting problems.

OVERSPEED OR UNDERSPEED SHUT DOWN

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 31

GENERATOR OUTPUT CONNECTION LUGS

DANGER

RUN CABLES THROUGH SLOTS

The generator is equipped with connection lugs behind the lug box door located on the lower portion of the control box. 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 HIGHL Y 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 National Electric Code (NEC) as well as any local or state guidelines as

required by law. Failure to follow proper installation requirements may result in

equipment or property damage, p erson a l inj u ry or deat h.

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. Potentially lethal

voltages may be present at the generator connection lugs.

IMPROPER OR INCORRECT CONNECTIONS TO A BUILDINGS ELECTRICAL SYSTEM

CAN CAUSE POTENTIALLY LETHAL VOLTAGES TO BACKFEED ONTO UTILITY

LINES. THIS MAY RESULT IN INJURY OR ELECTROCUTION TO UTILITY WORKERS

NEARBY. MAKE SURE THE GENERATOR IS SUPPLING POWER TO AN ISOLATED

OBJECT OR BUILDING THAT IS NOT CONNECTED TO ANY UTILITY LINES.

Connections to the lugs should be made by running the power cables up through the slot in the bottom of the box. Use a hex-wrench to tighten the cable connections. The connection lug door is equipped with safety interlock switches that will trip the main circuit breaker and disable the voltage regulator if the door is opened while the unit is operating.

WARNING

Never attempt to disable or modify the lug door safety s witches. Equipment damage,

personal injury or death may result.

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

NATIONAL ELECTRIC CODE (NEC) AS WELL AS ANY STATE OR LOCAL GUIDELINES OR CODES.

Page 32

GENERATOR CAM LOCK CONNECTIONS (OPTIONAL)

DANGER

L1 L2

N (Neutral)

G (Ground)

Black Red

Blue White Green

LOCK

DOUBLE CAM LOCK PANELSINGLE CAM LOCK PANEL

The generator may be equipped with cam lock connections behind the door on the right side of the customer convenience outlets. These receptacles 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 HIGHL Y 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 state guidelines

as required by law. Failure to follow proper installation requirements may result in

equipment or property damage, p erson a l inj u ry or deat h.

WARNING

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

breaker and the engine st art switch are in the OFF “O” posit ion and that the negative

(-) battery cable is disconnected. Potentially lethal voltages may be present at the

generator connection lugs.

IMPROPER OR INCORRECT CONNECTIONS TO A BUILDINGS ELECTRICAL SYSTEM CAN CAUSE POTENTIALL Y LETHAL VOLT AGE TO BACKFEED ONTO UTILITY LINES. THIS MA Y RESULT IN INJUR Y OR ELECTROCUTION TO UTILITY WORKERS NEARBY .

MAKE SURE THE GENERATOR IS SUPPLYING POWER TO AN ISOLATED OBJECT

OR BUILDING THAT IS NOT CONNECTED TO ANY UTILITY LINES.

Connections should be made by plugging power cables equipped with series 16 taper nose 400A, 600V cam lock plugs into the cam lock receptacles. Secure the connection by rotating the plug a 1/4 turn to the right. The cam lock connection 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 on the far right of the cam lock panel. The unit MUST be connected to a good earthen ground for proper operating safety. The ground connection SHOULD BE IN COMPLIANCE WITH THE NATIONAL

ELECTRIC CODE (NEC) AS WELL AS ANY STATE OR LOCAL GUIDELINES OR CODES.

Some units are equipped with two sets of cam lock connections. Make sure all

connections to the cam lock receptacles are made to one side only, below each

corresponding breaker. i.e. DO NOT attach L1, L2 and L3 t o the left side and Neutral

WARNING

and Ground to the right side.

Page 33

VOLTAGE SELECTOR SWITCH (MMG150 & MMG170 ONLY)

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. Voltage ranges are selected by rotating the handle on the switch to the desired voltage.

NEVER CHANGE THE VOLTAGE SELECTOR SWITCH WHILE THE ENGINE IS RUN-

NING! 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

L-L

T11

T10

T4 T1

N =

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

120V 120V

L1 - N = 120V L3 - N = 120V

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, volt age at the two GFCI duplex convenience outlets is 139 V olts and the vo ltage at the thr ee twist-lock outlet s is 240/139 V olts. When the volt age 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.

Page 34

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. Voltage ranges are selected by rotating the handle on the switch to the desired voltage.

NEVER CHANGE THE VOLTAGE SELECTOR SWITCH WHILE THE ENGINE IS RUN-

NING! 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 outlet s is 139 Volts and the volt age at the three twist-lock outlets is 139/240 Volts. When the voltage selector switch is in position for 120/208V 3Ø, voltage at the two GFCI duplex convenience ou tlets is 120 V olts and the voltage at the th ree twist-lock outlets is 120/ 208 Volts. When the voltage selector switch is in position for 120/240 3Ø (DELTA), voltage at the two GFCI dup lex 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 voltage at the three twist-lock outlets is 120/240 Volts.

Page 35

CHANGING OUTPUT VOLTAGE (MMG235 ONLY)

DANGER

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 voltage, shut the generator down and make sure that the main circuit breaker and the control power switch are in the off “O” position.

NEVER ATTEMPT TO CHANGE THE VOLTAGE WHILE THE ENGINE IS RUNNING.

LETHAL VOLTAGE MAY BE PRESENT AT THE CONNECTION LUGS ON THE RECON-

NECT BOARD.

To receive 480/277 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 STARTUP section, beginning on page 22.

REMOVE ALL

1/2” NUTS

T10

T11

T12

L-N

L-L

LINK BOARD ATTACHED IN

480 VOLT 3Ø POSITION

T10

L-L

T12

T11

L-N

LINK BOARD ATTACHED IN

208 VOLT 3Ø POSITION

Page 36

EMERGENCY STOP SWITCH

ON/I

OFF/O

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.

Use the EMERGENCY STOP switch only when the generator must be shut down immedi-

ately. For any other shut down, follow the detailed procedure on page 24.

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:

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 (shorting board) is removed.

Make sure that any problems that cause the main circuit breaker to trip are corrected before returning the switch to the on “I” position.

WARNING

The main circuit breaker interrupt s power to the customer connection lugs on ly! The

customer convenience outlets have power even if the main circuit brea ker is in the

OFF “O” position. T o disconnect power to the co nvenience outlets, use the individual

circuit breakers located near each outlet.

VOLTAGE REGULATION

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

Page 37

CUSTOMER CONVENIENCE OUTLETS

120V DUPLEX

CONVENIENCE

OUTLETS

50A CIRCUIT

BREAKERS

20A CIRCUIT

BREAKERS

120/240V TWIST LOCK CONVENIENCE OUTLETS

OUTLET PANEL FOR UNITS

EQUIPPED WITH CAM LOCKS

120V DUPLEX

CONVENIENCE OUTLETS

50A CIRCUIT

BREAKERS

20A CIRCUIT

BREAKERS

120/240V TWIST LOCK

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 VAC duplex receptacles 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.

Power to the outlets is available any time the generator is running, EVEN IF THE MAIN CIRCUIT BREAKER IS OFF “O”. MAKE SURE THAT ANY EQUIPMENT CONNECTED TO THE 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 outlets. Improper voltage may

cause equipment damage or malfunction.

Note: When the shorting board is in position for 480/27 7V 3Ø, volt age at th e two GFCI duplex convenien ce outlet s is 139 Volts and the voltage at the three twist-lock outlets is 240/139 Volts. When the shorting board is in position for 208/120V 3Ø, voltage at the three twist-lock outlets and the two GFCI outlets is 208/120 volts.

DERATING FOR ALTITUDE

All generator sets are subject to derating for altitude and temperature; this will reduce the available power for operating of tools and accessories connected to the auxiliary outlets. Typical 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 above 72º F (22.2º C).

REMOTE START TERMINAL BLOCK

The remote start terminal block is located just to the right of the three twist-lock 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, 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 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 GENERATOR START UP on page 22.

REMOTE

START

SWITCH

TERMINALS

Page 38

TRANSFER SWITCH

DANGER

INCOMING

UTILITY POWER

WHITE = INCOMING UTILITY POWER

GRAY = NORMAL UTILITY POWER CIRCUIT

BLACK = EMERGENCY GENERATOR POWER CIRCUIT

UTILITY

METER

TRANSFER

SWITCH

MAIN DISTRIBUTION

PANEL

(UTILITY POWER)

EMERGENCY

DISTRIBUTION PANEL

(GENERATOR POWER)

POWER FROM

GENERATOR

When the generator is used as a standby power supply, it must be equipped with a transfer switch which isolates it from the utility’s distribution system. A transfer switch is designed to transfer electrical loads from the normal power source (utility) to the emergency power source (generator) when normal voltage falls below a prescribed level. The transfer switch automatically returns the load back to the normal source when power is restored back to operating levels.

FAILUR E TO ISOLA TE THE GENER A TOR FROM THE NO RMAL POWER UTILITY CAN CAUSE POTENTIALL Y LETHAL VOL TAGE TO BACKFEED INTO THE UTILITY LINES. THIS MA Y RESULT IN INJUR Y OR ELECTROCUTION OF UTILITY WORKERS NEARBY . MAKE SURE THE GENERA TOR IS ISOLATED BY A TRANSFER SWITCH FROM ANY

LOCAL UTILITY LINES. THIS ALSO APPLIES IF THE GENERATOR IS BEING USED

AS A BACK UP TO SOME OTHER TYPE OF POWER SUPPLY.

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.

Page 39

WARNING

CAUTION

It is strongly recommended that ONLY a licensed electrician perform any wiring and any related connections to the generator . Inst allation should be in compliance of the National Electric Code (NEC) as well as any state or local codes or regulations. Failure to follow these procedures could result in property damage, p ersonal 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.

When using the generator as a standby or substitute power supply, make sure the output

voltage and phase rotation of the generator match those of the local power utility. Improper

voltage or phase rotation may cause equipment damage or malfunction.

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 off. When servicing this equipment always follow the instructions listed below.

• Before servicing the 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 the 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 before each use. If wet, dry the unit thoroughly before starting.

DAILY WALK AROUND INSPECTION

Look for conditions that could hinder performance or safety, such as (but not limited to) oil/coolant/fuel leakage, blocked vents, loose/missing hardware and electrical connections.

Visually inspect the fan belt for cracks, fraying, stretching and that the belt is properly seated in pulley grooves. Replace the belt according to the manufacturer’s recommendations.

Note: At the 500 hour/12 month service interval, it is recommended that the belt be removed and checked for wear. While the belt is removed, inspect pulleys and bearings. Rotate and fee l for hard turning or unusual sounds. If pulleys or bearings need replacement contact John Deere.

Failure to perform a daily inspection may result in serious damage to the prime mover.

BELT TENSION

John Deere engines use two types of belt tensioners: manual and automatic. Adjust the belt using the manual tensioner according to the manufacturer’s specifications. The automatic tensioner cannot be adjusted or repaired and is designed to maintain proper tension over the belt’s life. Units with the automatic belt tensioner must be inspected according to the manufacturer’s specifications.

Page 40

ENGINE BREAK-IN REQUIREMENTS

Note: During the first 20 hours of operation, avoid long periods of no load o r sust ai ned maxim um 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 OPERATION 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.

DAILY 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. H

ITEM DAILY

Check engine oil level  Check air cleaner and filter minder gauge*  Check engine coolant level  Visual walk around inspection  Check fuel filter  Service battery  Inspect radiator for blockage, clean as necessary  Change engine oil and replace filter**  Replace fuel filter element  Inspect oil vapor recirculation filter (if equipped)  Check air intake hoses, connections and system  Check automatic belt tensioner and belt wear  Check cooling system  Perform coolant solution analysis  Replace oil vapor recirculation filter (if equipped)  Pressure test cooling system  Flush cooling system***  Check and adjust engine valve clearance  Check generator drive plate torque (see procedure

on page 42)****

HRS.

250

HRS.

0).

500

HRS.

1000

HRS.

ANNUALLY



* Replace primary air cleaner when restriction indicator shows a vacuum of 25 in. H ** Change the oil and oil filter after the first 100 hours, then every 250 hours.

Page 41

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

6-Stud Sequence

5-Stud Sequence

8 -Stud Sequence

OPERATION AND MAINTENANCE MANUAL.

**** Check the torque of the generator drive plate bolts after the first 250 hours of operation, then annually.

LIFTING THE GENERATOR

CENTRAL LIFT EYE

A large central lifting eye is located on the top of the generator. The eye is connected to a central lifting frame inside the unit. Attach a sling or hook directly to the lifting 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 - 11. Always remain aware of others around you when moving or lifting the generator. Keep the cabinet doors closed and locked.

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. Raise the jack foot completely.

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 properly latched.

4. Check for proper inflation of the trailer tires. Maximum tire pressures can be found on pages 9 - 11.

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.

TRAILER WHEEL BEARINGS

Some trailers are 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

Page 42

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.

AUXILIARY FUEL TANK OPTION

The auxiliary fuel tank option is desgined so the unit can run from an external fuel tank. The unit is still programed to shut down when the internal tank’s fuel level drops below five percent. In order for the unit to run off of an auxiliary tank, the fuel level in the internal tank must remain over five percent. To operate the unit using an auxiliary fuel tank, use the following procedure:

1. Shut down the unit and check that the level of fuel in the tank is above five percent.

2. Attach the auxiliary fuel tank's fuel lines to the “AUXILIARY FUEL INLET” and “AUXILIARY FUEL OUTLET” fittings on the unit.

3. Open the “AUXILIARY FUEL INLET” and “AUXILIARY FUEL OUTLET” valves located inside of the right front door.

FUEL TRANSFER PUMP OPTION

The fuel transfer pump option allows the fuel tank to be refilled from an external bulk fuel source. When the fuel transfer switch is on, anytime the fuel level drops below 15% the fuel transfer pump will begin pumping fuel from an external bulk fuel source into the fuel tank on the unit. The fuel transfer pump will shut off when the fuel level of the internal tank reaches 90%. The pump will also be monitored to ensure a certain percentage increase in fuel level over a given period of time to prevent the pump from running dry. To operate the fuel transfer system, use the following procedure:

1. Shut down the unit. Note: if the external bulk fuel supply is already connected, the

unit does not have to be shut down to turn the fuel transfer pump option on or off.

2. Attach the external bulk fuel supply to “FUEL TRANSFER INLET” fitting on the unit.

3. Turn on the Fuel Transfer Switch.

FUEL TRANSFER

CHECKING GENERATOR DRIVE PLATE TORQUE

Follow the procedure below to check the torque of the generator drive plate bolts in accordance with the maintenance chart on page 40.

1. Remove the generator fan guard.

2. Torque each of the drive plate bolts to the appropriate specification shown in the table below.

Unit FT/LB

MMG150 46

MMG170 46

MMG235 46

INLET

3. Reinstall the generator fan guard.

Page 43

TRAILER WIRING DIAGRAM

TRAILER

PLUG

AMBER

MARKER

AMBER

MARKER

FENDER

MARKER

LAMP

RED

LAMP

PLATE

LAMP

IDENTIFICATION

LIGHT BAR

AMBER

MARKER

LAMP

AMBER

MARKER

LAMP

FENDER

RED

MARKER

LAMP

STOP-TURN

SIGNAL LAMP

(LEFT)

STOP-TURN

SIGNAL LAMP

(RIGHT)

Page 44

ELECTRIC BRAKE WIRING HARNESS

TO BRAKES

LEFT TURN/STOP

RIGHT TURN/STOP

TAIL/MARKER

GROUND

+ BATT -

BREAK

AWAY SW

BLU

BLK

GREEN

YELLOW

BROWN

WHITE

Page 45

BREAKER

240V 50A

BRN

240V 50A

BREAKER

240V 50A

BREAKER

BLK

BRN

10 14

BLK

PAIR BLK

GRN/YEL

(T7)

CT-3

BRN/WHT

L2 L3

SHUNT

CT-2CT-1

BLK

GRN/YEL

PAIR BLK

BRN/WHT

(2.5K, 2 WATT)

ADJUSTMENT

VOLTA GE

GROUND

TO GEN FRAME

60HZ

50HZ

ON REGULATOR

4 AMP FUSE

WHT

RED F+

F-

F+

BRN/WHT

BLK

BLK F-

BRN

MECHANICAL LUGS

GROUND

FRAME

BLK

50A

240V

RCPT.

BLK

GFCI

RECPT

120V

RCPT.

240V

50A

RCPT.

240V

BLK

T6T8T10

T11T7T1

T12

GENERATOR

F+

F-

120V

20A

BRKER

120V

RECPT

GFCI

SE350

VOLTAGE REGULATOR

12VDC

(T9)

GRN/YEL

BRKER

20A

120V

GND

BLK

RED

LUG DOOR

SAFETY SWITCH

LT BLU

BLK

PAIR BLK

(L0)

COM

H1 H3 X4X2H2H4

X1 X3

BLK

RED

WHT

QTY 2 BRN

BLK

RELAY

BUCK XFORMER

WHT

BLK

(3) JUMPER

WIRES ON PHASE

SWITCH 15-20,

12-17, 10-21

WIRES NOT USED IN

BUCK BOOST OPTION

SEE DC WIRING DIAGRAM FOR CT CONNECTIONS

BUCK BOOST OPTION

MAIN

CIRCUIT

BREAKER

VOLTAGE

SENSING RELAY

21 PIN

PLUG

AC WIRING DIAGRAM: MMG150-MMG170

Page 46

AC WIRING DIAGRAM: MMG150-MMG170 - 4-POSITION PHASE SWITCH

FRAME

GROUND

GEN

BOX

F-

F+

120V

MECHANICAL LUGS

GFCI

RECPT

GND

L2 L3

LUG DOOR

SAFETY SWITCH

120V

20A

BRKER

6GA

GRN/YEL

6 AWG

GRN/YEL

GROUND

TO GEN FRAME

CIRCUIT

BREAKER

SHUNT 12VDC

BRN/WHT

GENERATOR

T10

T11

(3) JUMPER

WIRES (DASHED)

T12

BLK

10 14

ORN

TP3A

RCPT.

240V

50A

RCPT.

240V

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

RELAY

VOLT REGULATION

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

BLK F+

BRN

BRN/WHT

BLK F-

WHT

BLK

F+

F-

SE350

VOLTAGE REGULATOR

4 AMP FUSE

50HZ

60HZ

ON REGULATOR

BLK

VOLTAGE RELAY

BRN

BUCK BOOST OPTION

RELAY

COM

X2 X4H3H1

RED

BUCK XFORMER

WHT

GN/YL

BR/WT

YL/WT

OR/WT

BLK

X3X1

WHT

INPUTS

GEN VOLTAGE

CT3

CT2

CT COMMON

COM

CT1

INPUTS

GENERATOR CURRENT

4 PIN PLUG 4 PIN PLUG

ELECTRONIC CONTROL BOARD

Page 47

BREAKER

240V 50A

BREAKER

240V 50A

BREAKER

BLK 10GA

800A

LT BLU 10GA

GRN/YEL 10GA

(T7)

CT-3

L2 L3

SHUNT

CT-2CT-1

BREAKER

QTY 3 BLK 3/0

GRN/YEL 14GA

GRN/YEL 10GA

PAIR BLK 6GA

(2.5K, 2 WATT)

ADJUSTMENT

VOLTAGE

GROUND

TO GEN FRAME

60HZ

50HZ

ON REGULATOR

4 AMP FUSE

WHT

BLK F+

F-

F+

BRN/WHT

BLK

BLK F-

BRN

MECHANICAL LUGS

GROUND

FRAME

BLK

50A

240V

RCPT.

BLK

GFCI

RECPT

120V

RCPT.

240V

50A

RCPT.

240V

BLK

GENERATOR

F+

F-

120V

20A

BRKER

120V

RECPT

GFCI

3/0

SE350

VOLTAGE REGULATOR

12VDC

(T9)

GRN/YEL 14GA

BRKER

20A

120V

GND

(L0)

PAIR BLK 6GA

LT BLU 10GA

BLK

RED

6 AWG

CIRCUIT

BOARD

RECONNECT

T10, T11, T12

T4 T6

T8T7

L2 L3

480V SHORT

208V SHORT

T10

T11

T12

T1T2T3T4T5

3/0

QTY 3 BLK 3/0

RECONNECT

DOOR

SAFETY SWITCH

COM

H1 H3 X4X2H2H4

X1 X3

BLK 10GA

RED 10GA

WHT 10GA

WHT 14GA

QTY 2 BRN 14

BLK 10GA

RELAY

BUCK XFORMER

VOLTAGE RELAY

WHT 10GA

BLK 14GA

PLUG 1

23-PIN

TO LUG DOOR SW SEE DC PRINT

TO 21 POS PLUG SEE DC PRINT

21 PIN

PLUG

AC WIRING DIAGRAM: MMG235

Page 48

AC WIRING DIAGRAM: MMG235 - 4-POSITION PHASE SWITCH

RELAY

VOLT REGULATION

GRN

ORN

YEL

3564

RED

BRN

BRN/W

T3T2T1T4T5

7011 19 32 8

GENERATOR

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

RCPT.

240V

50A

BLK

BREAKER

240V 50A

BLK 10GA

(T7)

240V

BLK

240V 50A

BLK 10GA

PAIR BLK 6GA

50A

RCPT.

BLK

BREAKER

BLK 10GA

(T9)

PAIR BLK 6GA

LT BLU 10GA

(L0)

PAIR BLK 6GA

LT BLU 10GA

BLK

WHT/BR

FRAME

GROUND

F-

T12

F+

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

VOLTAGE

(2.5K, 2 WATT)

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

ON REGULATOR

BRN

50HZ

60HZ

RED 10GA

BUCK XFORMER

H1 H3 X4X2H2H4

WHT 10GA

WHT 14GA

X1 X3

WHT 10GA

Page 49

PLUG LOCATION

2 PIN PLUG (RPM)

RPM IN

RPM GND

MAG IN

MAG REF

D+

PLUG LOCATION PIN

POWER + DC

RELAY BOARD

D+

BOTTOM

E STOP

BI1

7 PIN PLUG (BINARY INPUTS)

BO1

C1 +12VDC

LOCATION

CONTROL

POWER

SWITCH

RD/BK

BLK

RD/BK

LARGE 4 PIN PLUG (GEN VOLTAGE)

PHASE A VOLTAGE

PHASE B VOLTAGE

PHASE C VOLTAGE

LOCATION

PINPLUG LOCATION

NEUTRAL

L2L3N

PHASE C CURRENT

PHASE B CURRENT

PHASE A CURRENT

4 PIN PLUG (GEN CURRENT)

PLUG LOCATION

LOCATION

PHASE GND

COM

PLUG LOCATION

C+

STARTER

RELAY

B+

678

GTB

2/B

GROUND TERMINAL BLOCK

MJB

RD/VI

12 V

BATTERY

BLK

GROUND TO

ENGINE BLOCK

12/B

15A

BR/WT

YL/WT

OR/WT

GRN

WHT

ORN

YEL

BRN

GRY

WT/VI

GY/OR

BLK

YEL

RED

RD/WT

RED

WT/VI

BLK

YEL

BLK

RED

RD/WT

BLK

RED

GN/YL

BLK

REMOTE START

CONTACTS

ORN

RD/YL

ORN

FUEL

LEVEL

GROUND

TO TANK

WT/VI

21-PIN G

"RUN"

DEUTSCH

RD/VI

DEUTSCH

21-PIN J

ALT. EXCITE

ORN

MOTOR

STARTER

B+

F+

RED

LUG DOOR

SAFETY

ORG

RED

SWITCH

LOCATION

WATER IN

FUEL IN

OIL IN

3 PIN PLUG (ANALOG INPUTS)

PLUG LOCATION

WHT

AI1 (OIL)

AI3 (FUEL)

AI2 (TEMP)

REMOTE START

BI2

BI3

BI4

BI5

BI6

OPEN

LOW COOLANT OPTION

C2 +12VDC

BO2

SRT

FUE

BO3

BO4

BO5

BO6

OPEN

GND ON BOARD

BO2 FUEL

BO1 START

COM

ECU COM

LOCATION

PLUG LOCATION

ECU H

3 PIN PLUG

ECU L

SHIELD

BLK

GRY

DEUTSCH

21-PIN F

CAN-SHLD

CAN-L

21-PIN U

DEUTSCH

21-PIN V

CAN-H

BLK

Shield not connected

Cut back and Tape

RED

GEN FIELD

LOW

COOLANT

GY/BK

BLK

ALT

B+

RED

GY/BK

BLK

CT-1

CT-2

CT-3

WHT

GRN

BLK

BRN

YEL

ORN

L1 L2 L3

SHUNT

WHT

GRN

WHT

SPLICE

YEL

ORN

MAIN

BREAKER

BOTTOM

TOP

BOTTOM

LEFT SIDE

GN/YL

RD/WT

123456789

BLK

OPTIONAL

BATTERY

DISCONNECT

XTUVWMNP RSHJ KLC

GRY

SHLD

RED

BLK

GEN

F-

RED

GEN

F+

E-STOP

SWITCH

RD/WT

ORN

GN/YL

GRY

E-STOP

SWITCH

NO NO

BLK

RED

F-

BLK

VOLTAGE

REGULATOR

RED

SHLD

GRY

BLK

RD/VI

GY/BK

BLK

GRY

GN/YL

ORN

RD/WT

BLK

ORN

VIO

BLK

GRN

BLK

OPEN

POWER - DC

BO7

OPEN

RD/YL

RD/WT

BI7

OPEN

MDC CONTROLLER

90208, ORG 7.25.08

*NOT REQUIRED WITH JOHN DEERE ECU ENGINE

DC WIRING DIAGRAM: MMG150-MMG170

Page 50

DC WIRING DIAGRAM: MMG235

SWITCH

SAFETY

LUG DOOR

BLK

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

BLK

L1 L2 L3

YEL

BRN

L2L3N

678

2/B

BLK

GRN

BLK

WHT

SPLICE

WHT

SHUNT

YEL

MAIN

BREAKER

BLK

CT-1

WHT

ORN

BR/WT

LOCATION

GN/YL

SPLICE

BLK

CT-2

WHT

YL/WT

ORN

15A

BLK

CT-3

WHT

OR/WT

ORG

GRN

COM

BLK

ORN

RED

GRN

MJB

RED

YEL

123456789

RELAY

STARTER

RED

BLK

4 POS PHASE

RED

ORN

BLK

RED

C+

B+

POWER

SWITCH

CONTROL

R/BLK

SWITCH ONLY

TO PHASE SW

SEE AC PRINT

LOCATION

RD/WT

RD/BK

RD/WT

BLK

YEL

D+

RD/YL

BLK

RD/WT

C1 +12VDC

RD/YL

RD/BK

C2 +12VDC

BO1 START

RD/VI

BO3

BO2 FUEL

BO4

BO5

SAFETY

SWITCH

LUG DOOR

BO6

BO7

TO 3 POS LUG BLOCK T7 SEE DC PRINT

TO VOLTAGE REGULATOR 3 SEE DC PRINT

F+

VOLTA GE

REGULATOR

F-

GRY

BI1

LOCATION

RED

BLK

BRN

BLK

GRY

BR/WT

RD/WT

ORN

GN/YL

GRY

RED

BLK

GY/BK

WT/VI

ORN

RD/VI

BLK

GRY

SHLD

GY/OR

BI2

GY/BK

BI3

RED

BLK

XTUVWMNP R SHJK LC

BLK

ORN

BLK

SHLD

BLK

GRY

BI6

BI4

BI5

RED

12 V

BATTERY

OPTIONAL

DISCONNECT

BLK

BRN

BLK

GRY

BR/WT

RED

GY/BK

WT/VI

RD/VI

GRY

RD/WT

ORN

GN/YL

GRY

DEUTSCH

GEN

LOW

21-PIN J

DEUTSCH

CAN-H

21-PIN V

21-PIN F

DEUTSCH

CONTACTS

REMOTE START

RECONNECT

NO NO

F+

F-

GEN FIELD

COOLANT

ALT. EXCITE

21-PIN U

DEUTSCH

CAN-SHLD

DOOR SW

CAN-L

BLK

NO24NC

SWITCH

E-STOP

SWITCH

E-STOP

FUEL

VIO

B+

RED

B+

GROUND TO

ENGINE BLOCK

TO TANK

GROUND

LEVEL

21-PIN G

DEUTSCH

SHIELD

BLK

GRY

LOCATION

MOTOR

STARTER

ALT

"RUN"

Cut back and Tape

Shield not connected

COM

2 PIN PLUG (RPM)

BOTTOM

MDC CONTROLLER

PLUG LOCATION

BOTTOM

3 PIN PLUG (ANALOG INPUTS)

MAG REF

PLUG LOCATION

MAG IN

OIL IN

TOP

PHASE A VOLTAGE

PHASE B VOLTAGE

PHASE C VOLTAGE

FUEL IN

LARGE 4 PIN PLUG (GEN VOLTAGE)

WATER IN

NEUTRAL

4 PIN PLUG (GEN CURRENT)

TOP

PHASE C CURRENT

PHASE B CURRENT

PHASE A CURRENT

PLUG LOCATION

PHASE GND

RELAY BOARD

PLUG LOCATION PIN

BOTTOM

POWER + DC

D+

POWER - DC

BO1

3 PIN PLUG

OPEN

6 PIN PLUG (BINARY INPUTS)

PLUG LOCATION

BOTTOM

E STOP

REMOTE START

LOW COOLANT OPTION

RECONNECT DOOR

OPEN

PLUG LOCATION

LEFT SIDE

ECU H

ECU COM

ECU L

OPEN

FUE

SRT

BO2

*NOT REQUIRED WITH JOHN DEERE ECU ENGINE

Page 51

SERVICE LOG

OIL GRADE AND TYPE: ____________________________ BRAND:___________________________________

COOLANT MIXTURE: ______________________________ BRAND:___________________________________

__________________________________________________________________________________________

Page 52

REV: F PART NO: 26277

01.11.10

Magnum MMG150, MMG170, MMG235 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual