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Summary of Contents for Magnum MMG150
- Page 1 DIESEL GENERATOR MMG150 • MMG170 • MMG235 OPERATING MANUAL...
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Page 2: Introduction
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. -
Page 3: Table Of Contents
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 ................... -
Page 4: Safety Notes
SAFETY NOTES 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. -
Page 5: Engine Safety
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. -
Page 6: Towing Safety
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. -
Page 7: Unit Serial Number Locations
UNIT ID Tag PRODUCTS LLC MADE IN USA 215 Power Drive Berlin, WI 54923 1-800-926-9768 V.I.N. Tag Model Serial Number DATE: MANUFACTURED BY/FABRIQUE PAR: MAGNUM PRODUCTS LLC COLD INFL. PRESS./PRESS. Mfg. Code GVWR/PNBV: DE GONF A FROID GAWR/PNBE TIRE/PNEU RIM/JANTE KPA(PSI/LPC) SGL/DUAL amb. -
Page 8: Safety Symbol Summary
SAFETY SYMBOL SUMMARY 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. -
Page 9: Specifications
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) ........ - Page 10 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 MMG170 MMG170 Super Start Engine Make/Brand..............
- Page 11 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 MMG235 MMG235 Super Start Engine Make/Brand..............
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Page 12: Unit Dimensions
UNIT DIMENSIONS 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. -
Page 13: Service Locations
SERVICE LOCATIONS... -
Page 14: Main Control Panel Features, Standard
MAIN CONTROL PANEL FEATURES, STANDARD... - Page 15 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.
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Page 16: Main Control Panel Features, With Optional Cam Locks
MAIN CONTROL PANEL FEATURES, WITH OPTIONAL CAM LOCKS OPERATION CONTROL CONTROL MAN AUT MANUAL AUTO ENGINE ENGINE Ready START START 0.00 CONTROL CONTROL ALARM FAULT ENGINE ENGINE CANCEL RESET STOP STOP DIAGNOSTICS STATUS PAGE ALARM/FAULT WARNING SELECT READY/MANUAL READY/AUTO ENTER RUNNING SUPPLYING LOAD... - Page 17 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.
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Page 18: Magnum Digital Controller (Mdc)
MAGNUM DIGITAL 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;... -
Page 19: Generator Monitoring
• “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. - 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°...
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Page 21: Fine Voltage Adjustment
FINE VOLTAGE ADJUSTMENT Upon start-up of the generator, the “Running” screen of the Magnum Digital VOLTAGE Controller (MDC) will display “SENSING” and will countdown from 45 seconds CONTROL ADJUSTMENT to “0” Zero. This is a safety feature of the controller to protect the generator RHEOSTAT from over or under voltage upon start-up. -
Page 22: Pre - Start Check List
PRE - START CHECK LIST 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. - 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.
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Page 24: Auto" (Remote) Starting Of The Generator
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. -
Page 25: Mdc Controller Information Displays, Functions And Reset
MDC CONTROLLER INFORMATION DISPLAYS, FUNCTIONS AND RESET 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. -
Page 26: Magnum Digital Controller (Mdc)- List Of Possible Alarms/Descriptions
MAGNUM DIGITAL CONTROLLER (MDC)- LIST OF POSSIBLE ALARMS/DESCRIPTIONS Shut down and warning fault conditions and the displayed message are described in the following table: Information on Protection Events Specification Binary Output Description Type Available Shutdown alarm configurable on the input of IG- AnInIOM Sd IOM/IGS-PTM. -
Page 27: John Deere Ecu Information Displays And Functions
JOHN DEERE ECU INFORMATION DISPLAYS AND FUNCTIONS 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. -
Page 28: Mdc Controller (Mdc) - History
MDC CONTROLLER (MDC) – HISTORY 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. -
Page 29: Resetting Of The "Time To Service" Reminder
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”... - 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.
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Page 31: Generator Output Connection Lugs
GENERATOR OUTPUT CONNECTION LUGS 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. -
Page 32: Generator Cam Lock Connections (Optional)
GENERATOR CAM LOCK CONNECTIONS (OPTIONAL) 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 HIGHLY RECOMMENDED that only a trained and licensed electrician perform any wiring and related connections to the generator. -
Page 33: Voltage Selector Switch (Mmg150 & Mmg170 Only)
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. -
Page 34: 4-Position Voltage Selector Switch (Optional)
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. -
Page 35: Changing Output Voltage (Mmg235 Only)
CHANGING OUTPUT VOLTAGE (MMG235 ONLY) 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”... -
Page 36: Emergency Stop Switch
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
CUSTOMER 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. -
Page 38: Transfer Switch
TRANSFER SWITCH 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. -
Page 39: Engine And Generator Maintenance
WARNING It is strongly recommended that ONLY a licensed electrician perform any wiring and any 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. -
Page 40: Engine Break-In Requirements
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. The engine is supplied with engine break-in oil from the factory. -
Page 41: Lifting The Generator
*** If engine manufacturer’s recommended coolant is used, the flushing interval may be extended. See engine 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. -
Page 42: Auxiliary Fuel Tank Option
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 MMG170 MMG235 3. Reinstall the generator fan guard. -
Page 43: Trailer Wiring Diagram
TRAILER WIRING DIAGRAM TRAILER PLUG AMBER AMBER MARKER MARKER LAMP LAMP AMBER AMBER MARKER MARKER LAMP LAMP FENDER FENDER IDENTIFICATION MARKER MARKER LIGHT BAR LAMP LAMP PLATE LAMP STOP-TURN STOP-TURN SIGNAL LAMP SIGNAL LAMP (LEFT) (RIGHT) -
Page 44: Electric Brake Wiring Harness
ELECTRIC BRAKE WIRING HARNESS... -
Page 45: Ac Wiring Diagram: Mmg150-Mmg170
AC WIRING DIAGRAM: MMG150-MMG170... -
Page 46: Ac Wiring Diagram: Mmg150-Mmg170 - 4-Position Phase Switch
AC WIRING DIAGRAM: MMG150-MMG170 - 4-POSITION PHASE SWITCH... -
Page 47: Ac Wiring Diagram: Mmg235
AC WIRING DIAGRAM: MMG235... -
Page 48: Ac Wiring Diagram: Mmg235 - 4-Position Phase Switch
AC WIRING DIAGRAM: MMG235 - 4-POSITION PHASE SWITCH... -
Page 49: Dc Wiring Diagram: Mmg150-Mmg170
DC WIRING DIAGRAM: MMG150-MMG170... -
Page 50: Dc Wiring Diagram: Mmg235
DC WIRING DIAGRAM: MMG235... -
Page 51: Service Log
SERVICE LOG OIL GRADE AND TYPE: ____________________________ BRAND:___________________________________ COOLANT MIXTURE: ______________________________ BRAND:___________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________... - Page 52 REV: F PART NO: 26277 01.11.10...
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