Magnum MMG75D Operating Manual Download

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DC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT

DEUTSCH

21 PIN

CONN-2

EDISON PLUG

16/3

BRN

BLU

YEL/GRN

CLUTCH

RELA

CONT

BO7

BOTT

E ST

BI1

6 PIN PLUG (BINAR

INPUTS)

LOCA

TION

LOCA

TION

PLUG LOCA

TION

REMOTE ST

BI2

BI3

BI4

BI5

BI6

RECONNECT

DOOR

OPEN

FUEL

XFER ENABLE

LOW COOLANT

OPTION

4 PIN PLUG (BINAR

OUTPUTS)

PLUG LOCA

TION

BO3

BO4

BO5

BO6

OPEN

FUEL

XFER

OPEN

BOTT

MTB

FUEL

TRANSFER

ENABLE SW

Y/VIO

BLK/WHT

Y/VIO

RED/WHT

RED/VIO

FUEL

TRANSFER

PUMP

FUEL

XFER

RELA

GND

BAR

GND

BAR

BLK/WHT

CONN-2

21 PIN

DEUTSCH

31 PIN

RD/WT

FUEL

XFER

RELA

GND

BAR

BK/WT

CONN-2

21 PIN

31 PIN

FIL

HEA

EST

RD/VI

FUSE

SPLICE

GND

BAR

BK/WT

RD/BK

CONN-2

21 PIN

DEUTSCH

31 PIN

DEUTSCH

31 PIN

CONN-2

BK/WT

RD/BK

MMG 405

& 465 ONL

25A

FUSE

LOCA

TION

BINAR

OUT

BO3

BO4

BO5

BO6

BK/YL

HIGH IDLE

RELA

RD/OR

MTB

RD/WT

21 PIN

CONN-2

DEUTSCH

1.3K OHM

300 OHM

4 PIN PLUG

RD/YL

WT 6

WT 4

WT 12

WT 8

GY/OR

21 PIN

CONN-2

DEUTSCH

RD/VI

SPLICE

31 PIN

DEUTSCH

CONN-1

MAIN POWER

SWITCH

LIGHT

ENABLE

SWITCH

DOOR SWITCH

FLIPHOOD

4 DOOR

CONTROL

LIGHT

MTB

LIGHT

SWITCH

45678

INTERIOR

CABINET

LIGHT

MTB

TTER

CHARGER

TTER

12 V

BLK

RED

TTER

CHARGER

12 V

BLK

TTER

DISCONNECT

TTER

DISCONNECT

TTER

CLUTCH

GY/OR

BK/WT

BAR

87A

GY/OR

RD/BK

CLUTCH

87A

FUEL

TRANSFER

PUMP

HEA

FIL

TER

FUEL

87A

MTB

GY/OR

CONTROL

POWER SWITCH

TT+

MTB

INTERIOR

LIGHT

INTERIOR

LIGHT

RD/BK

SOLAR

CHARGE

MODULE

TTER

12 V

BLK

RED

SOLAR BA

TTER

CHARGER

HIGH

IDLE

87A

BO7

BO6

BO5

BO4

D+

RELA

BOARD

PLUG

LABEL

REMOTE ST

REMOTE

COMMUNICA

TION

BI2

E-ST

SWITCH

DETECT

LEAK

FLOA

BI4

90416_H_01.24.13

COM

REMOTE COMMUNICA

TION

RELA

BOARD

Summary of Contents for MMG75D

Page 1: ...Parts manuals available online www m p llc com POWER PRODUCTS LLC DIESEL GENERATOR 75 MMG75D MMG100D OPERATING MANUAL...

Page 2: ...ne operators 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...

Page 3: ...GITAL CONTROLLER MDC GENERATOR OPERATIONAL STATUS 29 MAGNUM DIGITAL CONTROLLER MDC ALARM MANAGEMENT 29 MAGNUM DIGITAL CONTROLLER MDC LIST OF ALARMS 30 JOHN DEERE ECU INFORMATION DISPLAYS AND FUNCTIONS...

Page 4: ...AC WIRING DIAGRAM 4 POSITION VOLTAGE SELECTOR SWITCH OPTION 48 AC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT 49 DC WIRING DIAGRAM 50 DC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT 51 WIRING BLOCK DIAGRAM DEDI...

Page 5: ...This Page Intentionally Left Blank 5...

Page 6: ...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...

Page 7: ...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 corresp...

Page 8: ...commended speed for highway towing is 45 mph 72 km h Recommended off road towing speed is not to exceed 10 mph 16 km h or less depending on terrain Before towing the trailer check that the weight of t...

Page 9: ...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 an individual problem between you your dealer or Magnum...

Page 10: ...is area Isolate generator to prevent electrocution hazard Use clean diesel fuel only Never change switch position while engine is running Remove negative battery cable before performing any service on...

Page 11: ...69 86 70 88 Amps 3 Standby 480V 208V A 103 239 106 244 3 Prime kW kVA 62 77 63 79 Amps 3 Prime 480V 208V A 93 214 95 219 1 Standby kW kVA 60 60 66 66 Amps 1 Standby 240V A 250 275 1 Prime kW kVA 56 5...

Page 12: ...107 88 110 Amps 3 Standby 480V 208V A 129 297 132 305 3 Prime kW kVA 78 98 80 100 Amps 3 Prime 480V 208V A 118 272 120 278 1 Standby kW kVA 75 75 78 78 Amps 1 Standby 240V A 313 325 1 Prime kW kVA 71...

Page 13: ...lled 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 CHAN...

Page 14: ...Drive Berlin WI 54923 1 800 926 9768 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 R...

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

Page 16: ...5 6 7 9 10 11 1 8 4 3 12 AUTO EXHAUST FILTER CLEANING LIMPIEZA AUTOM TICA DE FILTRO DE ESCAPE AUTOMATISCHE ABGASFILTERREINIGUNG NETTOYAGE DU FILTRE D CHAPPEMENT AUTO ENABLE EINSCHALTEN ACTIVAR ACTIVER...

Page 17: ...y require Ground Fault Circuit Interrupt GFCI protection 7 50A CIRCUIT BREAKERS 2 Circuit breakters for the 120 240V twist lock outlets 8 REMOTE START TERMINAL BLOCK Used to connect the generator to a...

Page 18: ...stment 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...

Page 19: ...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 and ready for the remote start signal Running I...

Page 20: ...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: ...s section gives an explanation of the indicators that are displayed on the DPF Status screen on the Magnum Digital Controller Diesel exhaust filter information can be found on the Liquid Crystal Displ...

Page 22: ...p of the generator the Running screen of the Magnum Digital Controller MDC will display V Detect and will count down from 45 seconds to zero This is a safety feature of the controller to protect the g...

Page 23: ...nerator display screen must be within 10 of the 208 120V position 188 228V line to line 108 132V line to neutral Note Each time the voltage selector switch is changed from one setting to another an ad...

Page 24: ...of this manual Make sure the control ON OFF toggle switch is in the OFF O position Make sure the circuit breakers main and convenience are switched OFF O Check that the generator is properly grounded...

Page 25: ...name unit model number part number of the programmed controller along with its revision and the company website along with their number 3 The LCD window will indicate MAN manual mode and Ready The Rea...

Page 26: ...he 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...

Page 27: ...ntacts 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...

Page 28: ...sition 3 Toggle to the DPF Status screen on the Magnum Digital Controller and verify the Disabled Regener ation indicator appears above the words DPF Inhib For information regarding the DPF Status scr...

Page 29: ...n 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 du...

Page 30: ...Wrn Fuel Level setpoint 12 GCB fail SD NO Failure of the generator circuit breaker 13 Igen unbl SD NO The generator current is unbalanced 14 Low BackupBatt WRN NO RTC backup battery is flat 15 Oil Pr...

Page 31: ...ce 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 d...

Page 32: ...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...

Page 33: ...current service time hour setting remaining 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 u...

Page 34: ...and then check the level of coolant in theradiator Toaccess the radiatorcap you mustremove the access panel from thetop of the enclosure directly above the radiator Add coolant until it is 3 4 in 2 c...

Page 35: ...ALSYSTEM 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 SUPPLYING POWER TO AN ISOL...

Page 36: ...zed personnel from changing the switch settings Note UNITS WITHOUT A CONVENIENCE OUTLET BUCK TRANSFORMER When the voltage selector switch is in position for 480 277V 3 voltage at the two GFCI duplex c...

Page 37: ...in place you will prevent unauthorized personnel from changing the switch settings Note UNITS WITHOUT A CONVENIENCE OUTLET BUCK TRANSFORMER When the voltage selector switch is in position for 277 480V...

Page 38: ...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 run...

Page 39: ...tlets 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 3 voltage at the three twist lock outlets and the two GFCI outle...

Page 40: ...rections 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 Fam...

Page 41: ...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...

Page 42: ...over BASIC MAINTENANCE SCHEDULE JOHN DEERE ENGINE Refer to the original equipment manufacturer s operating manual for a complete list of maintenance requirements Failure to comply with the procedures...

Page 43: ...tem contains a diesel particulate filter DPF Over time the DPF will require professional servicing to remove ash buildup The expected service interval will be at least 3000 or 4500 hours based on engi...

Page 44: ...vice 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...

Page 45: ...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 FUE...

Page 46: ...oling system efficiency The cooling fan will engage at full speed when the coolant temperature rises When the fan is operating at full speed it will switch to a slower speed when the coolant temperatu...

Page 47: ...7 BRN WHT BLK BLK F BRN MECHANICAL LUGS GROUND TO FRAME BLK BLK 50A 240V 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...

Page 48: ...RCUIT BREAKER BLK BLK BLK BLK BLK BLK BLU BLU BLU BLU 20 AMP G F I OUTLET 20 AMP G F I OUTLET 20 AMP 20 AMP 60HZ 50HZ ON REGULATOR 4 AMP FUSE WHT RED F F F 6 7 BRN WHT BLK BLK F BRN SE350 VOLTAGE REGU...

Page 49: ...BRN BRN BR WT OFF P N DEUTSCH 21 PIN CONN 1 CONN 2 31 PIN DEUTSCH 3 2 OR F F CONN 2 21 PIN DEUTSCH M 15 DEUTSCH 31 PIN CONN 2 OR TO T8 LUG DOOR RECONNECT DOOR PMG S R BRN BRN BR WT DEUTSCH 21 PIN CON...

Page 50: ...HUNT WHT MAIN BREAKER L0 LOWER LOWER UPPER UPPER LOWER LEFT SIDE RED WHT RED WHT 10 1 2 3 4 5 6 7 8 9 X T C A W M N P R S H J K L U E B V D F G GRY SHLD BLK GEN F RED GEN F RED WHT ORN GRN YEL GRY E S...

Page 51: ...LAY 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 V...

Page 52: ...IG 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...

Page 53: ...WT WT WT WT AMBER MARKER LAMP BK BK WT WT RED MARKER LAMP BK BK BK BK LAMP MARKER WHITE WT WT BK BK LAMP MARKER RED WT WT STOP TURN SIGNAL LAMP RIGHT LEFT SIGNAL LAMP STOP TURN WT WT BK BK RD RD WT W...

Page 54: ...E 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 BRA...

Page 55: ..._____________ __________________________________________________________________________________________ __________________________________________________________________________________________ ____...

Page 56: ...REV B PART NO 32668 03 15 13...

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