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Magnum MMG 125, Operating Manual, Page: 1 / 48

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www m-p-llc com

DIESEL GENERATORS

MMG 125 • MMG 155
MMG 180 • MMG 230

OPERATING MANUAL

Summary of Contents for MMG 125

Page 1: ...230 www m p llc com DIESEL GENERATORS MMG 125 MMG 155 MMG 180 MMG 230 OPERATING MANUAL ...

Page 2: ...tion 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 operators manual was also supplied with the unit at the time of shipment from the factory The manual provides detailed operation and maintenance procedures for the engine Additional copies of the engine operators manual are...

Page 3: ...U INFORMATION DISPLAYS AND FUNCTIONS 25 MDC CONTROLLER HISTORY 26 ADJUSTING THE DISPLAY BACKLIGHTING 26 RESETTING THE TIME TO SERVICE REMINDER 27 TROUBLESHOOTING AUTOMATIC SHUTDOWN CONDITIONS 27 28 GENERATOR OUTPUT CONNECTION LUGS 29 VOLTAGE SELECTOR SWITCH 30 4 POSITION VOLTAGE SELECTOR SWITCH OPTIONAL 31 CHANGING OUTPUT VOLTAGE MMG 230 32 EMERGENCY STOP SWITCH 33 MAIN CIRCUIT BREAKER 33 VOLTAGE ...

Page 4: ...ut Equipment connected to the generator overheats Sparking occurs Engine misfires or there is excessive engine generator vibration Operating on a combustible surface Protective covers are loose or missing If the ambient air temperature is above 110 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...

Page 5: ...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 i...

Page 6: ...s 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 ...

Page 7: ...F A FROID GAWR PNBE TIRE PNEU RIM JANTE KPA PSI LPC SGL DUAL 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...

Page 8: ...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...

Page 9: ...375 161 372 3Ø Prime kW kVA 99 124 97 121 Amps 3Ø Prime 480V 208V A 149 344 146 336 1Ø Standby kW kVA 97 97 105 105 Amps 1Ø Standby 240V A 404 438 1Ø Prime kW kVA 90 90 95 95 Amps 1Ø Prime 240V A 375 396 Frequency Hz 60 60 Power Factor 1 1Ø 0 8 3Ø 1 1Ø 0 8 3Ø Sound dB A 23 ft prime 68 68 Weights Dry Weight Skid Mounted lbs kg 5734 2601 6206 2815 Operating Weight Skid Mounted lbs kg 7474 3390 7946 ...

Page 10: ... 468 220 508 3Ø Prime kW kVA 125 156 132 165 Amps 3Ø Prime 480V 208V A 188 434 198 458 1Ø Standby kW kVA 100 100 143 143 Amps 1Ø Standby 240V A 417 596 1Ø Prime kW kVA 95 95 130 130 Amps 1Ø Prime 240V A 396 542 Frequency Hz 60 60 Power Factor 1 1Ø 0 8 3Ø 1 1Ø 0 8 3Ø Sound dB A 23 ft prime 68 68 Weights Dry Weight Skid Mounted lbs kg 5826 2643 6568 2979 Operating Weight Skid Mounted lbs kg 7566 343...

Page 11: ...8 251 580 3Ø Prime kW kVA 145 181 152 190 Amps 3Ø Prime 480V 208V A 218 502 229 527 1Ø Standby kW kVA 125 125 163 163 Amps 1Ø Standby 240V A 521 679 1Ø Prime kW kVA 120 120 150 150 Amps 1Ø Prime 240V A 500 625 Frequency Hz 60 60 Power Factor 1 1Ø 0 8 3Ø 1 1Ø 0 8 3Ø Sound dB A 23 ft prime 68 68 Weights Dry Weight Skid Mounted lbs kg 6300 2858 6765 3069 Operating Weight Skid Mounted lbs kg 8890 4032...

Page 12: ... 254 208 260 Amps 3Ø Standby 480V 208V A 306 705 313 722 3Ø Prime kW kVA 186 232 189 236 Amps 3Ø Prime 480V 208V A 279 644 284 655 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 Sound dB A 23 ft prime 68 68 Weights Dry Weight Skid Mounted lbs kg 6510 2953 7330 3325 Operating Weight Skid Mou...

Page 13: ...f 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 Dimensions L x W x H MMG 125 155 MMG 180 230 Skid Mounted in m 132 x 50 x 73 3 35 x 1 27 x 1 85 132 x 50 x 77 3 35 x 1 27 x 1 96 Trailer Mounted in m 210 x 86 x 90 5 33 x 2 18 x 2 29 210 x 86 x 93 5 33 x 2 18 ...

Page 14: ...SERVICE LOCATIONS 14 ...

Page 15: ... 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 START TERMINAL BLOCK Used to connect the generator to a dry contact closure switch for remote starting of the generator 12 OUTPUT GROUND CONNECTION Ground lu...

Page 16: ...OSTICS keypad and the STATUS Light Emitting Diodes LED s The following is a brief summary of the operation of each section of the control panel 1 The CONTROL ON CONTROL OFF Toggle Switch and Fine Voltage Adjustment Screw Control On Off Toggle Switch This toggle switch powers up the control panel and the controller Fine Voltage Adjustment Screw This screw may be adjusted to set the generator output...

Page 17: ...tatus of the generator Alarm Fault Indicates active or inactive alarms but not reset shutdown alarms Warning Indicates an active or inactive alarm or a warning alarm that has not been reset Ready Manual Indicates the controller is ready to start and in the manual mode Ready Auto Indicates the unit is in the AUTO mode ready for the remote start signal Running Indicates the unit is running Supplying...

Page 18: ...n Note The MLG 25 does not display fuel level Vbat Displays the engine battery voltage A normal reading is 13 14V on 12 volt systems and 24 26 on 24 volt systems with the engine running Additional information may be viewed while the unit is in MANUAL or AUTO mode By pressing the Page Select button the operator will select one of the following screens Running screen Password screen or History scree...

Page 19: ...crew 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 When making this adjustment if the voltage is increased or decreased too fast or too slow the unit will automatically shut down This adjustment needs...

Page 20: ...ctor 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 ...

Page 21: ...r 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 at tempts to start for a total of three crank cycles 9 Should the engine not start and run within 3 starting cycles the LCD window will show SD Start fail...

Page 22: ...th a transfer switch if the unit is to be used as a standby power supply as described on pages 35 and 36 Then continue with the steps described below 1 Perform a manual start of the generator at least once to verify that the engine is operating correctly 2 If a check of the remote start circuit is desired remove the wires from the remote start terminal block Press the AUTO button the Liquid Crysta...

Page 23: ... 2 Cooling The generator is cooling before stop 3 Cranking Engine is cranking 4 EmergMan Emergency Manual gen set operation 5 Init Autotest during controller power on 6 Loaded The generator is running at nominal speed and GCB OPEN CLOSE is closed 7 Not Ready The generator is not ready to start 8 Pause Pause between start attempts 9 Prestart Prestart sequence in process Prestart output is closed 10...

Page 24: ...of the generator circuit breaker 13 Igen unbl SD NO The generator current is unbalanced 14 Low BackupBatt WRN NO RTC backup battery is flat 15 Oil Press Sd SD NO Oil pressure is smaller than Sd Oil press setpoint 16 Oil Press Wrn WRN YES Oil pressure is smaller than Wrn Oil press setpoint 17 Overload SD YES The load is greater than the value given by Overload setpoint 18 Overspeed SD YES The prote...

Page 25: ...ine functions for a number of operation alarm and fault conditions When an opera tion 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 L...

Page 26: ...alog 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 Engi...

Page 27: ...der normal circumstances The engine controller will shut the engine down when there is 5 of fuel remaining in the tank This is done to keep the fuel lines from running dry 3 If the fuel level is good and no leaks are found check the fuel level sender and the connecting wiring for damage To check for continuity between the sender and the engine controller remove the bolts from the control panel and...

Page 28: ... the control panel and open the panel like a door Consult the appropriate DC wiring diagram in this manual for the proper path between the engine controller and the temperature sender 8 If the sender and wiring are good and no other problems are found remove the load on the generator and restart the engine Observe the coolant temperature and shut the engine down immediately if it starts to overhea...

Page 29: ...n SHOULD BE IN COMPLIANCE WITH THE NATIONAL ELECTRIC CODE NEC AS WELL AS ANY STATE OR LOCAL GUIDELINES OR CODES Before any connections are made to the generator make sure that the main circuit breaker and the engine start switch are in the OFF O position and that the negative battery cable is disconnected Potentially lethal voltages may be present at the generator connection lugs WARNING It is HIG...

Page 30: ...up and insert a padlock through the handle By locking the handle in place you will prevent unauthorized personnel from changing the switch settings Note When the voltage selector switch is in position for 480 277V 3Ø voltage at the two GFCI duplex conve nience outlets is 139 Volts and the voltage at the three twist lock outlets is 240 139 Volts When the voltage selector switch is in position for 2...

Page 31: ...d insert a padlock through the handle By locking the handle in place you will prevent unauthorized personnel from changing the switch settings Note The following applies to units without a convenience outlet buck transformer When the voltage selector switch is in position for 277 480V 3Ø voltage at the two GFCI duplex convenience outlets is 139 Volts and the voltage at the three twist lock outlets...

Page 32: ...er 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 START UP section beginning o...

Page 33: ...n 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 sto...

Page 34: ...NIENCE 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 voltage selector switch is in position for 480 277V 3Ø voltage at the two GFCI duplex conve nience outlets i...

Page 35: ...ich 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 INCOMING UTILITY POWER WHITE INCO...

Page 36: ...r 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 an...

Page 37: ...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 ...

Page 38: ...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 may be equipped with a grease zerk fitting to allow lubrication of the wheel bearings without the need to disassemble t...

Page 39: ...40V RCPT BLK GFCI RECPT 120V 17 21 25 18 22 26 19 20 23 24 27 28 T9 RCPT 240V 50A 50A RCPT 240V BLK BLK BLK T6 T8 T10 T11 T7 T1 T12 T2 T3 GENERATOR F F 120V 20A BRKER 120V RECPT GFCI L3 L2 L1 L0 SE350 VOLTAGE REGULATOR 12VDC T9 GRN YEL BRKER 20A 120V GND BLK RED LUG DOOR NO 12 11 SAFETY SWITCH LT BLU LT BLU LT BLU LT BLU LT BLU BLK BLK PAIR BLK L0 NC NO COM H1 H3 X4 X2 H2 H4 X1 X3 BLK RED WHT WHT ...

Page 40: ...0V RCPT BLK GFCI RECPT 120V RCPT 240V 50A 50A RCPT 240V BLK BLK 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 LT BLU 10GA LT BLU 10GA LT BLU 10GA BLK RED 6 AWG CIRCUIT BOARD RECONNECT T5 T10 T11 T12 T4 T6 T8 T7 L1 T9 L2 L3 T7 480V SHORT 208V SHORT T10 T11 T12 T1 T2 T3 T4 T5 T6 T8 T9 3 0 3 0 QTY 3 BL...

Page 41: ...ORG RED SWITCH 22 21 NC NC C LOCATION WATER IN FUEL IN OIL IN PIN 3 PIN PLUG ANALOG INPUTS PLUG LOCATION WHT AI1 OIL AI3 FUEL AI2 TEMP REMOTE START BI2 BI3 BI4 BI5 BI6 OPEN OPEN LOW COOLANT OPTION C2 12VDC BO2 SRT FUE BO3 BO4 BO5 BO6 OPEN OPEN OPEN OPEN GND ON BOARD BO2 FUEL BO1 START COM L H ECU COM PIN LOCATION PLUG LOCATION ECU H 3 PIN PLUG ECU L SHIELD BLK GRY DEUTSCH 21 PIN F CAN SHLD CAN L 2...

Page 42: ... AI2 TEMP REMOTE START BI2 BI3 BI4 BI5 BI6 OPEN OPEN LOW COOLANT OPTION C2 12VDC BO2 SRT FUE BO3 BO4 BO5 BO6 RECONNECT DOOR OPEN OPEN OPEN NOT REQUIRED WITH JOHN DEERE ECU ENGINE GND ON BOARD BO2 FUEL BO1 START COM L H ECU COM PIN 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 DEUTSCH 21 PIN V CAN H BLK Shield not connected Cut back an...

Page 43: ... 17 21 25 18 22 26 19 20 23 24 27 28 T9 RCPT 240V 50A 50A RCPT 240V BLK BLK BLK T6 T8 T10 T11 T7 T1 T12 T2 T3 GENERATOR F F 120V 20A BRKER 120V RECPT GFCI 6GA L2 SE350 VOLTAGE REGULATOR 6GA 6GA 12VDC T9 GRN YEL BRKER 20A 120V GND 3 JUMPER WIRES DASHED ON PHASE SWITCH 10GA BLK RED PLUG 21 PIN 6 AWG CIRCUIT 24 23 NO LUG DOOR NC 12 11 SAFETY SWITCH L3 L2 L1 N WHT YEL BRN ORN P P N N 34 33 29 30 36 35...

Page 44: ...E BLK BLK 50A 240V RCPT BLK GFCI RECPT 120V RCPT 240V 50A 50A RCPT 240V BLK BLK 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 LT BLU 10GA LT BLU 10GA LT BLU 10GA BLK RED 6 AWG CIRCUIT T7 T10 T11 T12 T3 T2 T1 T4 T5 T6 T8 T9 3 0 3 0 24 23 NC NO NC NO COM H1 H3 X4 X2 H2 H4 X1 X3 BLK 10GA RED 10GA WHT 1...

Page 45: ...TRAILER LIGHTS WIRING DIAGRAM 45 ...

Page 46: ...46 NOTES ...

Page 47: ...47 SERVICE LOG OIL GRADE AND TYPE BRAND COOLANT MIXTURE BRAND ...

Page 48: ...REV J PART NO 22070 10 20 08 ...

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