Magnum MMG25FHI Operating Manual Download

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SPECIFICATIONS - MMG25FHI

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 setup, use and service requirements.

SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

MAGNUM MODEL

MMG25FHI

MMG25FHI Super Start

Engine

Make/Brand...................................................................... Isuzu .............................................Isuzu

Model ............................................................................... 4LE1NYGV-03 ..............................4LE1NYGV-03

Horsepower - prime

hp (kW)

.......................................... 32.1 (23.9).....................................32.1 (23.9)

Horsepower - standby

hp (kW)

....................................... 35.3 (26.3).....................................35.3 (26.3)

Operating Speed

rpm

..................................................... 1800 ..............................................1800

Displacement

(L)

....................................................... 134 (2.2)........................................134 (2.2)

Cylinders - qty .................................................................. 4 ....................................................4

Fuel Consumption - 100% prime

gph (Lph)

................... 1.8 (6.8).........................................1.8 (6.8)

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

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

Battery Rating .................................................................. 720 CCA .......................................720 CCA

Generator

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

Model ............................................................................... 282PSL1505 (1705)......................283PSL1507 (1707)

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

Generator Set (Engine/Generator)

3Ø - Standby

kW (kVA)

................................................... 20 (25)...........................................22 (27)

Amps - 3Ø Standby

480V (208V) A

................................ 30 (69)...........................................32 (75)

3Ø - Prime

kW (kVA)

...................................................... 18 (23)...........................................19 (24)

Amps - 3Ø Prime

480V (208V) A

.................................... 28 (64)...........................................29 (67)

1Ø - Standby

kW (kVA)

................................................... 16 (16)...........................................21 (21)

Amps - 1Ø Standby - 240V

.......................................... 67 ..................................................88

1Ø - Prime

kW (kVA)

...................................................... 15 (15)...........................................19 (19)

Amps - 1Ø Prime - 240V

............................................. 63 ..................................................79

Frequency

.................................................................. 60 ..................................................60

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

Sound

dB(A) 23 ft @ prime

........................................... 66 ..................................................66

Weights

Dry Weight, Skid Mounted

lbs (kg)

................................. 2048 (929).....................................2139 (970)

Operating Weight, Skid Mounted

lbs (kg)

...................... 2517 (1142)...................................2608 (1183)

Dry Weight, Trailer Mounted*

lbs (kg)

............................ 2289 (1038)...................................2380 (1080)

Operating Weight, Trailer Mounted*

lbs (kg)

.................. 2758 (1251)...................................2849 (1292)

*Standard single axle trailer only. Consult factory for dual axle or custom trailer weights.

Capacities

Fuel Tank Volume

gal (L)

................................................ 106 (401).......................................106 (401)

Usable Fuel Volume

gal (L)

............................................ 95 (360).........................................95 (360)

Coolant (incl. engine)

qt (L)

............................................ 12.0 (11.4).....................................12.0 (11.4)

Oil (incl. filter)

qt (L)

........................................................ 8.6 (8.1).........................................8.6 (8.1)

Maximum Run Time

hrs

................................................. 45.4 ...............................................45.4

AC Distribution

Circuit Breaker Size ......................................................... 90 ..................................................90

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 .............................................................. 1 ....................................................1

Capacity - Axle Rating

lbs (kg)

....................................... 3500 (1588)...................................3500 (1588)

Tire Size

...................................................................... 15 ..................................................15

Brakes.............................................................................. N/A ................................................N/A

Hitch - Standard ............................................................... 2" Ball............................................2" Ball

Maximum Tire Pressure

psi

............................................ 50 ..................................................50

Summary of Contents for MMG25FHI

Page 1: ...Parts manuals available online www m p llc com POWER PRODUCTS LLC DIESEL GENERATOR MMG25FHI MMG35FHD www m p llc com 55 MMG45FHK MMG55FHD OPERATING MANUAL ...

Page 2: ...om the factory The manual provides detailed operation and maintenance procedures for the engine Additional copies of the engine operator s manual are available from the engine manufacturer MAGNUM POWER 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 parts QUESTIONS please contact the Magnum Power Produ...

Page 3: ...ERATOR 29 MDC CONTROLLER INFORMATION DISPLAYS FUNCTIONS AND RESET 29 MAGNUM DIGITAL CONTROLLER MDC GENERATOR OPERATIONAL STATUS 29 MAGNUM DIGITAL CONTROLLER MDC ALARM MANAGEMENT 30 MAGNUM DIGITAL CONTROLLER MDC LIST OF ALARMS 30 MAGNUM DIGITAL CONTROLLER MDC HISTORY 31 MMG ENGINE CONTROLLER 32 JOHN DEERE ECU INFORMATION DISPLAYS AND FUNCTIONS MMG55FHD ONLY 32 ADJUSTING THE DISPLAY BACKLIGHTING 33 ...

Page 4: ...ION 48 VISCOUS FAN CLUTCH OPTION 48 AC WIRING DIAGRAM 49 AC WIRING DIAGRAM 4 POSITION VOLTAGE SELECTOR SWITCH OPTION 50 AC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT 51 DC WIRING DIAGRAM MMG25FHI 52 DC WIRING DIAGRAM MMG35FHD MMG45FHK 53 DC WIRING DIAGRAM MMG55FHD 54 DC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT 55 WIRING BLOCK DIAGRAM DEDICATED 12 LEAD GENERATORS OPTION 56 TRAILER LIGHTS WIRING DIAGRAM 5...

Page 5: ...r 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 andcontrols Inexperiencedoperatorsshouldreceiveinstructionfromsomeone familiar withtheequipment before being allowed to operate or set up the generator The followi...

Page 6: ...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 le...

Page 7: ...een 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...

Page 8: ...ve 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 position of voltage selector switch while engine...

Page 9: ... Standby 480V 208V A 30 69 32 75 3Ø Prime kW kVA 18 23 19 24 Amps 3Ø Prime 480V 208V A 28 64 29 67 1Ø Standby kW kVA 16 16 21 21 Amps 1Ø Standby 240V A 67 88 1Ø Prime kW kVA 15 15 19 19 Amps 1Ø Prime 240V A 63 79 Frequency Hz 60 60 Power Factor 1 1Ø 0 8 3Ø 1 1Ø 0 8 3Ø Sound dB A 23 ft prime 66 66 Weights Dry Weight Skid Mounted lbs kg 2048 929 2139 970 Operating Weight Skid Mounted lbs kg 2517 114...

Page 10: ... 480V 208V A 43 100 46 105 3Ø Prime kW kVA 26 33 27 34 Amps 3Ø Prime 480V 208V A 40 92 41 94 1Ø Standby kW kVA 26 26 29 29 Amps 1Ø Standby 240V A 108 121 1Ø Prime kW kVA 25 25 26 26 Amps 1Ø Prime 240V A 104 108 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 2020 916 2074 941 Operating Weight Skid Mounted lbs kg 2475 1123 ...

Page 11: ...08V A 53 122 57 130 3Ø Prime kW kVA 33 41 34 43 Amps 3Ø Prime 480V 208V A 49 114 52 119 1Ø Standby kW kVA 33 33 36 36 Amps 1Ø Standby 240V A 138 150 1Ø Prime kW kVA 30 30 33 33 Amps 1Ø Prime 240V A 125 138 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 2329 1056 2524 1145 Operating Weight Skid Mounted lbs kg 3082 1398 327...

Page 12: ...80V 208V A 78 180 78 180 3Ø Prime kW kVA 47 59 47 59 Amps 3Ø Prime 480V 208V A 71 164 71 164 1Ø Standby kW kVA 49 49 50 50 Amps 1Ø Standby 240V A 204 208 1Ø Prime kW kVA 46 46 46 46 Amps 1Ø Prime 240V A 188 188 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 2570 1170 2640 1197 Operating Weight Skid Mounted lbs kg 3255 148...

Page 13: ...correctly 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 MODELS MMG25FHI MMG35FHD MMG45FHK MMG55FHD Dimensions L x W x H Skid Mounted in m 95 x 35 x 52 2 41 x 0 89 x 1 32 Trailer Mounted in m 150 x 57 x 67 3 81 x 1 45 x 1 70 H L W W L H ...

Page 14: ...Inc 215 Power Drive Berlin WI 54923 1 800 926 9768 VIN Tag TIRE AND LOADING INFORMATION RENSEIGNEMENTS SUR LES PNEUS ET LE CHARGEMENT SEE OWNER S MANUAL FOR ADDITIONAL INFORMATION VOIR LE MANUEL DE L USAGER POUR PLUS DE RENSEIGNEMENTS MANUFACTURED BY FABRIQUE PAR Magnum Power Products LLC DATE 00 0000 GVWR PNBV 000KG 0000LBS COLD INF PRESS PRESS DE V I N N I V 00000000000000000 TYPE TRAILER MODEL ...

Page 15: ...NS Engine Exhaust Engine Access Handle Central Lifting Eye Generator Access Secondary Hood Latch Fuel Fill Oil Drain Port Front Hood Latch Emergency Stop Control Panel and Voltage Selector Switch Access Radiator Drain Port ...

Page 16: ...16 MAIN CONTROL PANEL FEATURES 15 14 13 12 11 10 7 9 8 6 5 3 4 2 1 ...

Page 17: ...necting additional loads or equipment to the generator 10 ENGINE ACCESSORY CONNECTION Powers the battery charger and other engine accessories 11 GENERATOR GROUND CONNECTION LUG Allows connection to a good earthen ground per any local state or National Electric Code NEC guidelines before starting the generator 12 GENERATOR OUTPUT CONNECTION LUGS Allow appropriate loads to be wired directly to the g...

Page 18: ...ggleswitchandfinevoltageadjustment 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 Toggle Switch This toggle switch powers up the control panel and the controller Fine Voltage Adjustment Screw This screw may be adj...

Page 19: ...ght 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 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 t...

Page 20: ... down Vbat Displays the engine battery voltage A normal reading is 13 14V on 12 volt systems and 24 26V 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 ...

Page 21: ...r more the controller will shut the generator down automatically The display will read Wrn Gen L1 V Wrn Gen L2 V Wrn Gen L3 V or Sd Gen L1 V Sd Gen L2 V Sd Gen L3 V This means the controller warned Wrn or shutdown 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 adjust...

Page 22: ... the trailer 2 and a new nylon locking nut 4 Flip the trailer tongue down and reinstall the bolts and washers removed in step 2 using two new nylon locking nuts DO NOT reuse nylon locking nuts Tighten the bolts to 80 109 ft lbs 108 148 Nm Note If the jack was used to support the unit while removing the shipping brace the jack must be moved back to the tongue location before the unit can be towed C...

Page 23: ...nerator hoods are heavy Use caution when opening or closing TO CLOSE THE FRONT HOOD 1 Make sure the skid is free of debris and all personnel are clear of unit CAUTION Do not attempt to close the hood from the sides of the unit Proceed to the front of the unit and close the hood using the handle provided Failure to close the hood correctly could result in personal injury and equipment damage 2 Whil...

Page 24: ...and grip the lip of the emergency stop panel on the right side of the unit B With your left hand pull the hood latch located on the upper corner of the left hood side Refer to Figure C Tilt the hood completely open movement of the hood is limited by two metal guide straps CAUTION Generator hoods are heavy Use caution when opening or closing 5 Verify the red safety link is engaged and undamaged Thi...

Page 25: ...terclockwise Failure to release the safety link could result in damage to the link or other components CAUTION Do not attempt to close the hood from the sides of the unit Proceed to the rear of the unit and close the hood using the handle provided Failure to close the hood correctly could result in personal injury and equipment damage 4 While standing at the rear of the unit slowly push the hood f...

Page 26: ... of the generator covers loose or missing Are all preventive maintenance procedures up to date Check that the battery disconnect switch is on if equipped ENGINE BREAK IN REQUIREMENTS Note During the first 20 hours of operation avoid long periods of no load or sustained maximum load operation If the generator is to run for longer than five minutes without a load shut the generator down John Deere e...

Page 27: ...een ENGINE START button The Prestart 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 V Detect time delay will start to countdown ...

Page 28: ...rectly 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 pa...

Page 29: ...on 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 shutdown 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 followi...

Page 30: ...rting sequence due to bad battery condition it doesn t try to start again and activates this protection 4 Binary Input CONFIG YES Configurable Warning Shutdown alarms on the inputs of IL NT 5 ChrgAlternFail WRN YES Failure of the alternator to charge the battery 6 EmergencyStop SD NO If the red Emergency Stop switch is pushed or opened shutdown is immediately activated 7 Engine Temp Sd SD NO Water...

Page 31: ... of the engine can drop under Start RPM again Then the Underspeed protec tion becomes active Protection evaluation starts 5 sec onds after startup 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 Wrn ECU Alarm WRN NO ECU alarm list is not empty 30 Wrn RA15 f...

Page 32: ... a fault by using these codes refer to the John Deere Operator s 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 ...

Page 33: ...n The current service time hour setting 0 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 WrnMaintenance 6 Press the button and reset the current run time hour setting to 250 If you pass the 250 time interval use the button to get back to the 250 time interval 7 Press ENTER to save the cur...

Page 34: ...ator To access the radiator cap you must open the front hood Add coolant until it is 3 4 in 1 9 cm 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 ...

Page 35: ...or connection lugs DANGER IMPROPERORINCORRECTCONNECTIONSTOABUILDING SELECTRICALSYSTEM CAN CAUSE POTENTIALLY LETHAL VOLTAGE TO BACKFEED INTO UTILITY LINES THIS MAY RESULT IN INJURY OR ELECTROCUTION TO UTILITY WORKERS NEARBY MAKE SURE THE GENERATOR IS SUPPLYING POWER TO AN ISOLATED OBJECT OR BUILDING THAT IS NOT CONNECTED TO ANY UTILITY LINES Use a hex wrench to tighten the cable connections The lug...

Page 36: ...ETHAL VOLTAGE TO BACKFEED INTO UTILITY LINES THIS MAY RESULT IN INJURY OR ELECTROCUTION TO UTILITY WORKERS NEARBY MAKE SURE THE GENERATOR IS SUPPLYING POWER TO AN ISOLATED OBJECT OR BUILDING THAT IS NOT CONNECTED TO ANY UTILITY LINES Connections should be made by plugging power cables equipped with series 16 taper nose 400A 600V cam lock plugs into the cam lock receptacles Secure the connection by...

Page 37: ...ped with safety interlock switches If the door is opened while the unit is operating the safety interlock switches will trip the main circuit breaker and disable the voltage regulator The generator output will drop down to residual voltage WARNING Never attempt to disable or modify the lug door safety switches Equipment damage personal injury or death may result Note UNITS WITHOUT A CONVENIENCE OU...

Page 38: ... will drop down to residual voltage WARNING Never attempt to disable or modify the lug door safety switches Equipment damage personal injury or death may result Note UNITS WITHOUT A CONVENIENCE OUTLET BUCK TRANSFORMER When the voltage selector switch is in position for 480 277V 3Ø voltage at the two GFCI duplex convenience outlets is 139 volts and the voltage at the two twist lock convenience outl...

Page 39: ...tched to the ON I position 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 208 120V only 2 The door covering the customer connection lugs is opened 3 If the EMERGENCY STOP switch is activated Make sure any problems that cause the main circuit...

Page 40: ...ltage at the two twist lock outlets is 240 139 volts When the voltage selector switch is in position for 208 120V 3Ø voltage at the two twist lock outlets and the two GFCI duplex convenience 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 operation of tools and accessories connected to t...

Page 41: ... 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 the 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 W...

Page 42: ... is recommended the belt be removed and checked for wear While the belt is removed inspect pulleys and bearings Rotate and feel for hard turning or unusual sounds If pulleys or bearings need replacement contact the engine manufacturer ENGINE AND GENERATOR MAINTENANCE Check the engine oil level daily before starting the engine DO NOT start the generator if the oil level is below the ADD mark on the...

Page 43: ...complete list of maintenance requirements Failure to comply with the procedures as described in the engine operator s manual will nullify the warranty decrease performance and cause equipment damage or premature equipment failure Use the schedule in the following table as a guide for regular maintenance intervals For additional or replacement copies of the engine operator s manual contact an autho...

Page 44: ... air cleaner element yearly or after six cleanings whichever occurs first Maintenance Action Daily 50 Hrs 250 Hrs 500 Hrs 1 Year 2 Years Check oil level Check coolant level Check fuel level Check tire pressure Check all electrical connections Inspect radiator fins for debris clean as required Check fuel pipes and clamp bands Drain water separator Change engine oil Clean air cleaner element Clean f...

Page 45: ...il is used the interval can be increased to every 500 hours Item Daily 250 Hrs 500 Hrs 12 Months 2000 Hrs 24 Months As Required Check oil level Check coolant level Check fuel level Check tire pressure Check all electrical connections Inspect radiator fins for debris clean as required Check fuel filter Check air cleaner dust unloader valve and indicator Perform visual walkaround inspection Check oi...

Page 46: ...re all doors are closed and secure 4 Check for proper inflation of the trailer tires For maximum tire pressures refer to the Specifications section pages 9 12 5 Check the wheel lugs tighten or replace any that are loose or missing If a tire has been removed for axle service or replaced tighten the lugs in the order shown to the following specifications A Start all lug nuts by hand B First pass tig...

Page 47: ...oth sides of the tube If equipped the axle bolt and nut assembly of the caster wheel must also be lubricated with the same light weight oil TOP WIND MODELS Apply a lightweight oil to the screw stem CHECKING GENERATOR DRIVE PLATE TORQUE Follow the procedure below to check the torque of the generator drive plate bolts in accordance with the maintenance chart 1 Disconnect the engine starting battery ...

Page 48: ... 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 ...

Page 49: ...2 T11 BRK L1 BRK L2 GB T2 BRK L3 PS 16 BRK L3 PS 1 BRK L1 PS 13 GB T5 GB T4 GB T6 PS 26 GB T9 GB T8 GB T10 GB T11 PS 7 PS 6 PS 10 PS 2 PS 18 PS 25 GB T12 PB T9 PB T9 PB T7 LO GB T7 BRN WHT YEL WHT ORN WHT BLU BLK BLK BLU BLU RED BLK BLK BLK RED OR YL BLK WHT OR YL OR BK OR BK GRN GRN GRN GRN GRN GRN GRN 1 7 6 12 OR BK CT1 CT2 CT3 X1 X1 X1 GRN GRN GRN BRN WHT YEL WHT ORN WHT BRN YEL ORN MDC CONTROL...

Page 50: ...CT2 CT3 X1 X1 X1 GRN GRN GRN VOLT REGULATION RELAY YEL ORN BLK BLK GRN RED 3 5 6 4 1 8 7 2 BRN BRN REMOVED FOR BUCK BOOST OPTION L2 L3 L1 L0 MECHANICAL LUGS GND BLK T5 T6 T7 T8 CB L1 CB L2 CB L3 PS 1 PS 43 PS 24 PS 11 PS 7 PS 33 PS 2 PS 21 PS 27 1 7 6 12 36 40 8 12 16 4 20 24 28 32 34 33 29 37 38 35 39 5 9 13 6 10 14 1 2 17 21 25 18 22 26 7 11 15 3 19 23 27 30 31 GEN T7 GEN T12 GEN T2 GEN T5 GEN T...

Page 51: ... F CONN 2 21 PIN DEUTSCH M 15 DEUTSCH 31 PIN CONN 2 OR TO T8 LUG DOOR NON POWER ZONE RECONNECT DOOR PMG S R BN BN BR WT DEUTSCH 21 PIN CONN 2 BR WT BR WT USED ON BR WT CONN 2 31 PIN DEUTSCH 6 7 OR GN YL WT RECONNECT DOOR PMG S R BN BR WT DEUTSCH 21 PIN CONN 2 BR WT CONN 2 31 PIN DEUTSCH 6 7 OR T7 T9 L1 L3 L2 BREAKER CIRCUIT GEN T1 T2 T3 T4 NEUTRAL BAR L1 L2 L0 T7 T9 BR OR 34 33 SOME MODELS 33 34 C...

Page 52: ...BL BK WT GY BK BLK CLR WT VIO WT YL GY BK BLK MOTOR STARTER B B 12 V BATTERY BLK RED ORN RED START RELAY MAIN JUMPER BLOCK MJB LUG DOOR SAFTEY SWITCH RED BLK WHT CONTROL POWER SWITCH 1 2 RD WT BLK TB 2 1 REMOTE START CONTACTS L1 L2 L3 SHUNT WHT YEL MAIN BREAKER GLOW PLUG BLUE RD YL F TO GEN F F TO V GEN F BO7 OPEN BK YL BI7 OPEN RED 2 ORN RED BLUE VIO YEL RED YEL BLK BLK RED RED BLK BR WT YL WT OR...

Page 53: ... BL VIO GY BK BLK CLR WT VIO WT YL GY BK BLK MOTOR STARTER B B 12 V BATTERY BLK RED ORN SPLICE RED START RELAY MAIN JUMPER BLOCK MJB LUG DOOR SAFTEY SWITCH RED BLK CLR BLK BATT BATT ACT ACT PICKUP PICKUP GOVERNOR CONTROL VI YL VIO VIO BLK CLR F G H J D E CONTROL POWER SWITCH 1 2 RD WT BLK TB 2 1 REMOTE START L1 L2 L3 SHUNT WHT YEL MAIN BREAKER GLOW PLUG BLUE VIO F TO GEN F F TO V GEN F BO7 OPEN BK...

Page 54: ...MJB LUG DOOR SAFTEY SWITCH BLK CONTROL POWER SWITCH 1 2 RD WT BLK TB 2 1 REMOTE START CONTACTS F TO V GEN F BO7 OPEN BK YL BI7 OPEN RD 3 RED RD 2 VIO YEL BK WT BLK RED COM BLK 10 1 2 3 4 5 6 7 8 9 11 12 15A BLK BLK RED 2 RED RD WT YEL ORN ORN RED BK WT BLK COMMON BK WT BK WT TO GRD BAR FUSABLE LINK GRD TO BAR OPTIONAL GRD TO BAR GRY ORN RD WT VIO YEL RD VI REF AC DIAGRAM BLK GRD BAR TO PHASE C CUR...

Page 55: ...BK YL HIGH IDLE RELAY RD OR 8 MTB RD WT 21 PIN P N CONN 2 DEUTSCH 1 3K OHM 300 OHM 4 PIN PLUG RD YL WT RD BK BK BK BK WT 6 WT 4 WT 12 WT 8 WT GY OR 21 PIN T CONN 2 DEUTSCH RD VI RD SPLICE RD 31 PIN DEUTSCH CONN 1 MAY VARY 7 MTB 10 OR 12 POS FUSED POWER MTB 7 10 OR 12 POS FUSED POWER MAIN POWER SWITCH LIGHT ENABLE SWITCH DOOR SWITCH PANEL LIGHT PANEL LIGHT FLIPHOOD 4 DOOR CONTROL LIGHT LIGHT SWITCH...

Page 56: ...ZIG ZAG 480 240V 1 PH HIGH ZIG ZAG TO GENERATOR TO GENERATOR TO GENERATOR TO GENERATOR L9 L7 T10 T11 T12 T3 T9 T6 T8 T5 T2 T1 T7 T4 T1 T7 T8 T12 T3 T9 T11 T10 T5 T4 T9 T6 T5 T8 T11 T2 T10 T12 T7 T4 T1 T3 T10 T3 T9 T6 T1 T4 T7 T12 T5 T8 T2 T6 T2 T11 T9 T5 T3 T8 T4 T2 T10 T6 T7 T1 T12 T2 T8 T11 T12 T10 T6 T5 T4 T3 T9 T1 T7 L9 L7 L9 L7 L9 L7 L9 L7 T11 TO GENERATOR NOTE 1 CABLES TO CONTROL BOX MAY CON...

Page 57: ...57 TRAILER LIGHTS WIRING DIAGRAM 90387_ORG_10 04 12 GN YL BN WT GN YL BN WT BN BN WT WT RIGHT MARKER LAMP MARKER LAMP LEFT TRAILER PLUG RIGHT TAIL TURN LAMP LAMP TAIL TURN LEFT LAMP PLATE LICENSE ...

Page 58: ...KE OPTION 90286_D_10 31 12 BATTERY BREAKAWAY SWITCH BLU WHT BLK WHT WHT WHT WHT BRAKE BLU BLU BRAKE WHT BLU BLU BLU BLU WHT BRAKE BLU BLU BRAKE WHT WHT WHT TANDEM AXLE WHT BLU BRAKE WHT BLU BLU WHT BRAKE BLU WHT TRI AXLE SINGLE AXLE ...

Page 59: ...______________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ _____________________...

Page 60: ...REV B PART NO 29663 05 07 13 ...

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