Magnum MMG75CAN6 Operating Manual Download Page 48 | Manualshive

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48

WIRING HARNESS - ELECTRIC BRAKE OPTION

90286_D_10.31.12

BA

TTER

Y

BREAKA

W

A

Y

SWITCH

BLU

WHT

B

LK

WHT

W

HT

WHT

WHT

BRAKE

BLU

BLU

BRAKE

WHT

BLU

BLU

BLU

BLU

WHT

BRAKE

BLU

BLU

BRAKE

WHT

WHT

WHT

T

A

NDEM AXLE

WHT

BLU

BRAKE

WHT

BLU

BLU

WHT

BRAKE

BLU

WHT

TRI-AXLE

SINGLE AXLE

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Summary of Contents for MMG75CAN6

Page 1: ...Parts manuals available online www m p llc com POWER PRODUCTS LLC DIESEL GENERATOR www m p llc com MMG75CAN6 MMG100CAN6 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: ...L STATUS 23 MAGNUM DIGITAL CONTROLLER MDC ALARM MANAGEMENT 24 MAGNUM DIGITAL CONTROLLER MDC LIST OF ALARMS 24 JOHN DEERE ECU INFORMATION DISPLAYS AND FUNCTIONS 25 MAGNUM DIGITAL CONTROLLER MDC HISTORY 26 ADJUSTING THE DISPLAY BACKLIGHTING 27 RESETTING THE TIME TO SERVICE REMINDER 27 TROUBLESHOOTING AUTOMATIC SHUTDOWN CONDITIONS 27 GENERATOR OUTPUT CONNECTION LUGS 29 VOLTAGE SELECTOR SWITCHES 29 4 ...

Page 4: ...WIRING DIAGRAM MMG100CAN6 42 AC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT 43 DC WIRING DIAGRAM 44 DC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT 45 WIRING BLOCK DIAGRAM DEDICATED 12 LEAD GENERATORS OPTION 46 TRAILER LIGHTS WIRING DIAGRAM 47 WIRING HARNESS ELECTRIC BRAKE OPTION 48 SERVICE LOG 49 NOTES 50 ...

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: ... 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 ...

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: ...r 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 posi...

Page 9: ...VA 63 79 62 78 53 66 0 0 Amps 3Ø Standby A 76 93 184 0 3Ø Prime kW kVA 58 72 58 72 52 65 0 0 Amps 3Ø Prime A 69 87 180 0 1Ø Standby kW kVA 0 0 0 0 0 0 31 31 Amps 1Ø Standby 240V A 0 0 0 129 1Ø Prime kW kVA 0 0 0 0 0 0 29 29 Amps 1Ø Prime 240V A 0 0 0 121 Frequency Hz 60 Power Factor 1 1Ø 0 8 3Ø Sound dB A 23 ft prime 68 Weights Dry Weight Skid Mounted lbs kg 3178 1442 Operating Weight Skid Mounted...

Page 10: ...VA 85 106 77 96 66 83 0 0 Amps 3Ø Standby A 102 116 229 0 3Ø Prime kW kVA 78 97 72 90 62 78 0 0 Amps 3Ø Prime A 93 108 215 0 1Ø Standby kW kVA 0 0 0 0 0 0 37 37 Amps 1Ø Standby 240V A 0 0 0 154 1Ø Prime kW kVA 0 0 0 0 0 0 35 35 Amps 1Ø Prime 240V A 0 0 0 146 Frequency Hz 60 Power Factor 1 1Ø 0 8 3Ø Sound dB A 23 ft prime 68 Weights Dry Weight Skid Mounted lbs kg 3402 1543 Operating Weight Skid Mou...

Page 11: ...alled 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 MODELS MMG75CAN6 MMG100CAN6 Dimensions L x W x H Skid Mounted in m 96 x 38 x 62 2 44 x 0 97 x 1 58 Trailer Mounted in m 158 x 60 x 84 4 01 x 1 52 x 2 13 W L H W L H ...

Page 12: ... 800 926 9768 UNIT ID Tag Located on control panel 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 13: ...r Access Panel Engine Access Engine Access Engine Exhaust Emergency Stop Oil Drain Port Radiator Drain Port Control Panel Access Central Lift Point Fuel Fill LEFT SIDE RIGHT SIDE Voltage Selector Switch Access Engine Battery Access ...

Page 14: ...k 4 3 2 1 12 11 10 9 8 6 5 7 CAUTION Do not use 120V GFCI outlets when generator at 480 or 600 volts Equipment damage or personal injury may result CAUTION Do not use 240V twist lock outlets when generator at 600 volts Equipment damage or personal injury may result ...

Page 15: ...se switches operate optional control panel and interior lights 6 AIR FILTER METER This gauge shows the condition of the air filter when the engine is running 7 MAGNUM DIGITAL CONTROLLER MDC Refer to Magnum Digital Controller MDC on page 16 8 20A CIRCUIT BREAKERS Circuit breakers for the 120V GFCI receptacles 9 120V GFCI DUPLEX CONVENIENCE RECEPTACLES Used for connecting additional loads or equipme...

Page 16: ...ltage 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 toggle switch This toggle switch powers up and switches off the control panel and the controller Fine Voltage Adjustment Screw This screw may be adju...

Page 17: ...ing 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 the Auto m...

Page 18: ... 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 Battery Volts Displays the engine battery voltage A normal reading is 13 14V on 12 volt systems and 24 26V on 24 ...

Page 19: ...ntinuous black exhaust when the unit is under a constant load It can also cause fouling of injectors and buildup on engine valves Diesel engines operate properly when applied loads are between 30 and 100 capacity Appropriate generator sizing is determined by the anticipated load If the unit is in a wet stack condition load the unit heavily for five hours or until the exhaust is clear FINE VOLTAGE ...

Page 20: ... Check that the generator is properly grounded to a good earthen ground per any local and National Electric Code NEC regulations Verify all electrical connections at the connection lugs are tight and wired correctly 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 wate...

Page 21: ... 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 4 Press the green 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 di...

Page 22: ...shown as 0 until the engine temperature is approximately 100 F 38 C 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 Refer to Fine Voltage Adjustment on page 19 13 Check that the frequency Hz is...

Page 23: ...o OFFO 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 CONTR...

Page 24: ...oller opens outputs GCB CLOSE OPEN FUEL SOLENOID STARTER and PRESTART to stop the engine immediately No Events Specification Protection Type Information on Binary Output Available Description 1 AnInIOM Sd SD YES Shutdown alarm configurable on the input of IG IOM IGS PTM 2 AnInIOM Wrn WRN YES Warning alarm configurable on the input of IG IOM IGS PTM 3 Battery Flat low battery SD YES If the controll...

Page 25: ...ve 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 mea surement 21 Sd IOM fail SD NO Shutdown alarm in case of los...

Page 26: ...DC HISTORY The MDC stores a record of each important event in the history file of the controller The history file seats 117 records When the history file is full the oldest records are removed No SPN Description 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...

Page 27: ...play 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 button to move the cursor down to the Engine Protect line of text 4 Press ENTER WrnMaintenance will appear at the top left of the display screen The current service time hour setting remaining 0 will be one line below it on the right...

Page 28: ...ar milky if coolant is present Consult the engine operator s manual for additional information HIGH COOLANT TEMPERATURE SHUTDOWN 1 Check the coolant level in the overflow jug 2 Restart the engine and read the coolant temperature to verify a high coolant temperature shutdown Stop the engine immediately if the coolant temperature is 230 F 110 C or more 3 Allow the engine to cool Add coolant to the o...

Page 29: ...slots in the plastic cable guide at the base of the lug box DO NOT make any connections directly to the lugs The lug box door is equipped with a safety interlock switch that will automatically trip the main circuit breaker and disable the voltage regulator when the lug door is opened Use a hex wrench to tighten the cable connections WARNING Never attempt to disable or modify the lug door safety sw...

Page 30: ...eceptacles is 240 139 volts When the voltage selector switch is in position for 208 120V 3Ø voltage at the two twist lock receptacles and the two GFCI receptacles is 208 120 volts Unit Configuration Switch Configuration Voltage Configuration 600 348V 3 Phase 480 277V 3 Phase 208 120V 3 Phase 240 120V 1 Phase 208 120 480 277 600V 480V T1 L1 T4 T7 T10 N T2 L2 T8 T5 T9 T6 T3 L3 T11 T12 L N L L L1 L2 ...

Page 31: ...switch that changes the resistance to the voltage regulator to set the generator output voltage to 480V or 600V Voltage ranges are selected by rotating the handles on the switches 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 switches and generator windings The four position selector switch must be at 48...

Page 32: ...s 120 volts and the voltage at the three twist lock receptacles is 120 208 volts When the voltage selector switch is in position for 120 240 3Ø DELTA voltage at the two GFCI duplex convenience receptacles is 120 volts and the THREE TWIST LOCK RECEPTACLES SHOULD NOT BE USED When the voltage selector switch is in position for 120 240V 1Ø voltage at the two GFCI duplex convenience receptacles is 120 ...

Page 33: ...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 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...

Page 34: ...ed to the receptacles Improper voltage may cause equipment damage or malfunction 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 the auxiliary receptacles Typical reductions in performance are 2 4 for every 1000 ft 305 m of elevation and 1 per 10ºF 12ºC increase in...

Page 35: ...RNING ONLY a licensed electrician should perform wiring and related connections to the generator Installation 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 personal injury or death Before any connections are attempted make sure the main circuit breaker and the engine st...

Page 36: ... bottom of the crosshatch pattern DO NOT OVERFILL the crankcase Consult the engine operator s 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 FUL...

Page 37: ... 250 hours If John Deere Plus 50 II engine oil is used the interval can be increased to every 500 hours Item Daily 250 Hrs 500 Hrs 12 Months 3000 Hrs 36 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 water separator bowl Check air cleaner dust valve res...

Page 38: ...ecure 4 Check for proper inflation of the trailer tires For maximum tire pressures refer to the Specifications section pages 9 10 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...

Page 39: ...he torque of the generator drive plate bolts in accordance with the maintenance chart Refer to Basic Maintenance Schedule John Deere Engine on page 37 1 Disconnect the engine starting battery 2 Remove the generator fan guard 3 Torque each of the drive plate bolts to the appropriate specification in the table below 4 Reinstall the generator fan guard Reconnect the battery VISCOUS FAN CLUTCH The vis...

Page 40: ...ER 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 w...

Page 41: ...A 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 BK RD LUG DOOR NO 12 11 SAFETY SWITCH LT BLU LT BLU LT BLU LT BLU LT BLU BLK BLK PAIR BLK L0 3 JUMMPER WIRES ON PHASE SWITCH 15 20 12 17 10 21 WIRES NOT USED IN BUCK BOOST OPTION SEE DC WIRING DIAGRAM MAIN CIRCUIT BREAKER P P N N...

Page 42: ...GFCI L3 L2 L1 L0 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 3 JUMMPER WIRES ON PHASE SWITCH 15 20 12 17 10 21 WIRES NOT USED IN BUCK BOOST OPTION MAIN CIRCUIT BREAKER 21 PIN PLUG P P N N 2 5K 2 WATT ADJUSTMENT VOLTAGE 60HZ 50HZ ON REGULATOR 4 AMP FUSE WHT RED F F F 3 4 6 7 BRN WHT BLK BLK F BRN SE350 VOLTAGE RE...

Page 43: ...MG B V BN BR WT DEUTSCH 21 PIN CONN 1 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 CAM LOCK PANEL GND L0 L1 L3 L2 ALT POWER ZONE CONTROL ONLY 39 40 LUG DOOR NON POWER ZONE POWER ZONE CONTROL ONLY 39 40 NON POWER ZONE USED ON SOME MODELS NON POWER ZONE WHT WHT NOTE REPEAT ALT CAM LOCK FOR THIRD SET S R DEU...

Page 44: ... F CAN SHLD CAN L 21 PIN U DEUTSCH DEUTSCH 21 PIN V CAN H BLK SHIELD NOT CONNECTED CUT BACK AND TAPE TO GEN FIELD LOW COOLANT GRY BLK BLK ALT GRY BLK CT 1 CT 2 CT 3 WHT WHT GN YL BLK BLK BLK SPLICE OR LOWER LOWER UPPER UPPER LOWER LEFT SIDE RED WHT X T U V W M N P R S H J K L C D E F G A B GRY SHLD BLK GEN F RED GEN F RED WHT ORN GRN YEL GRY E STOP SWITCH NO NO 4A 3A 4 3 BLK RED RED F BLK RED SHLD...

Page 45: ...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 INTERIOR CABINET LIGH...

Page 46: ...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 47: ...47 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 48: ...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 49: ..._______________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ ____________________...

Page 50: ...___________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ ___________________________________________________________________...

Page 51: ...51 ...

Page 52: ...REV ORG PART NO 33791 08 22 13 ...

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