Related Manuals for Generac Power Systems MAGNUM MMG75D
Summary of Contents for Generac Power Systems MAGNUM MMG75D
- Page 1 DIESEL GENERATOR MMG75D • MMG100D With Controller 01886 OPERATING MANUAL Parts manuals available online at www.generacmobile.com 33701 C 02/16...
- Page 2 WARNING CALIFORNIA PROPOSITION 65 WARNING: Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. (000004) WARNING CALIFORNIA PROPOSITION 65 WARNING: This product contains or emits chemicals known to the state of California to cause cancer, birth defects, and other reproductive harm.
- Page 3 Introduction This manual provides information and procedures to safely operate and maintain the Generac Mobile Products unit. For your own safety and protection from physical injury, carefully read, understand, and observe the safety instructions described in this manual. Keep a copy of this manual with the unit at all times. Additional copies are available from Generac Mobile Products, or can be found at www.generacmobile.com.The information contained in this manual was based on machines in production at the time of publication.
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Page 5: Table Of Contents
Table of Contents Section 1 - Safety Safety Notes ............................1 Operating Safety..........................1 Engine Safety ............................. 2 Service Safety ............................ 2 Towing Safety............................. 3 Reporting Trailer Safety Defects ......................3 Safety Symbol Summary ........................4 Section 2 - General Information Specifications ............................. - Page 6 Section 4 - Maintenance Emissions Information ........................37 Daily Walk Around Inspection......................37 General Maintenance ........................37 Basic Maintenance Schedule ......................38 Engine Break-In Requirements ......................39 Resetting the Maintenance Alarms....................39 Exhaust Filter Service Requirements ....................40 Checking Generator Drive Plate Torque ..................40 Jack Maintenance..........................
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Page 7: Section 1 - Safety
Section 1 - Safety 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 8: Engine Safety
Safety 1. Noticeable change in engine speed. 2. Loss of electrical output. 3. Equipment connected to the unit overheats. 4. Sparking occurs. 5. Engine misfires or there is excessive engine/generator vibration. 6. Protective covers are loose or missing. 7. If the ambient air temperature is above 120°F (49°C). ENGINE SAFETY Internal combustion engines present special hazards during operation and fueling. -
Page 9: Towing Safety
Safety • DO NOT start the unit under load. The circuit breakers must be in the OFF (O) position when starting the unit in Manual mode. The circuit breakers can be in the ON (I) position only when started in the Auto mode. -
Page 10: Safety Symbol Summary
Safety You can also obtain other information about motor vehicle safety from http://www.safercar.gov. SAFETY SYMBOL SUMMARY The safety and operating decals affixed to the unit provide important 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 online parts manual at www.generacmobile.com. -
Page 11: Section 2 - General Information
Section 2 - General Information SPECIFICATIONS GENERAC MODEL MMG75D MMG75D Super Start Engine Make/Brand................John Deere......John Deere Model ..................PE4045HFG92 ......PE4045HFG92 EPA Tier ..................4i ..........4i Horsepower - Prime hp (kW) ..........97 (72) ........97 (72) Horsepower - Standby hp (kW) ..........107 (80) ........107 (80) Operating Speed rpm .............1800 ........1800 Displacement in (L) ..............274 (4.5) ........274 (4.5) - Page 12 General Information GENERAC MODEL MMG100D MMG100D Super Start Engine Make/Brand................John Deere......John Deere Model ..................PE4045HFG92 ......PE4045HFG92 EPA Tier ..................4i ..........4i Horsepower - Prime hp (kW) ..........121 (90) ........121 (90) Horsepower - Standby hp (kW) ..........133 (99) ........133 (99) Operating Speed rpm .............1800 ........1800 Displacement in (L) ..............275 (4.5) ........275 (4.5) Cylinders - qty .................4 ..........4...
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Page 13: Unit Dimensions
General Information Unit Dimensions 01887 Figure 2-1. Unit Dimensions A (Width) B (Length) C (Height) MMG75D/100D - Skid Mounted 40 in. (1.02 m) 119 in. (3.02 m) 62 in. (1.57 m) MMG75D/100D - Trailer Mounted 69 in. (1.75 m) 170 in. (4.32 m) 80 in. -
Page 14: Unit Serial Number Locations
General Information UNIT SERIAL NUMBER LOCATIONS Figure 2-2 for unit ID tag and Vehicle Identification Number (VIN) tag on the unit. Important information, such as the unit serial number, model number, VIN and tire loading information are found on these tags. Record the information from these tags so it is available if the tags are lost or damaged. -
Page 15: Component Locations
General Information COMPONENT LOCATIONS 01889 Figure 2-3. Component Locations Central lift point Oil drain port Voltage selector switch access Fuel fill Generator access Control panel access Manual holder access Emergency stop switch Engine exhaust Handle Front hood latch Radiator access Engine/battery access Engine access Radiator drain port... -
Page 16: Control Panel
General Information CONTROL PANEL 01890 Figure 2-4. Control Panel Component Locations Power Zone™ controller Cam lock connections (5) 50A circuit breakers (3) Generator ground connection lug 120V GFCI receptacles (2) Generator output connection lugs (4) 20A circuit breakers (2) Door safety switches (2) Remote start terminal block Diesel exhaust filter cleaning switch Engine accessory connection (2) -
Page 17: Power Zone™ Gen Controller
General Information POWER ZONE™ GEN CONTROLLER The Power Zone™ controller is an auto start controller that monitors the unit and indicates operational status and fault conditions. The controller can be programmed to automatically start or stop, based on time schedule, fault condition, or load demand. - Page 18 General Information Manual Mode Time to Empty 15 hr 100 110 Full 3 PHASE 106.9 kW Volts Amps Empty 00393 Figure 2-6. Home Button Screen Engine Button The Engine ( ) button displays the oil pressure, coolant temperature and battery voltage on three main gauges. Below the gauges is an hour gauge displaying the total run time on the engine.
- Page 19 General Information Generator Button The Generator ( ) button displays the average voltage frequency, volts and amps from the generator, as well as line-to-line voltage and individual line-to-neutral voltage, amperage and power (kW). This screen also displays the generator winding configuration set by the voltage selector switch in the lower right corner. Manual Mode Freq Volt...
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Page 20: Maintenance Screens
General Information Auto/Manual Mode Button The Auto/Manual Mode ( ) button is used to change the startup and shutdown modes of the unit. When pressed once, the unit enters Manual mode and when pressed and held for five seconds, the unit enters Auto mode. If in Auto mode, pressing once will return the unit to Manual mode. - Page 21 General Information Generator Summary The Generator Summary can be found at the top of all maintenance screens and provides an overview of the system. SITE GENSET 07:10 480V/277V 3-Phase Energy Generator Return Delay 10:00:00 Total kWh+ kVAr kVAh 0.00 kVArh kVAr 01781 Figure 2-10.
- Page 22 General Information SITE GENSET 7741 \ 7740 480V/277V 3-Phase 07:10 Return Delay 10:00:00 Total Generator kWh+ kVAr kVAh 0.00 kVAr kVArh Volt Volt Volt Freq L1-L2 L2-L3 L3-L1 Volt Volt kVAr L1-L2 L2-L3 L3-L1 Engine Generator Alarms Schedule Status 00399 Figure 2-12.
- Page 23 General Information SITE GENSET 7741 \ 7740 07:10 480V/277V 3-Phase Return Delay 10:00:00 Total Generator kWh+ kVAr kVAh 0.00 kVAr kVArh Index Date Time Event Details 01/01/1970 00:00:01 0:00 Shutdown This is an event index 1 02/06/1970 11:45:55 0:00 Shutdown This is an event index 2 Warning 01/01/1970...
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Page 24: Generator Monitoring
General Information SITE GENSET 7741 \ 7740 480V/277V 3-Phase 07:10 Return Delay 10:00:00 Total Generator kWh+ kVAr kVAh 0.00 kVAr kVArh Scheduler Enabled to run Reserved Reserved Event Week Start Stop Duration Event Week Start Stop Duration Monday 00:00 00:00 0:00 Monday 00:00... -
Page 25: Controller Information Displays, Functions, And Reset
General Information • HEST Lamp (High Exhaust System Temperature): This area will display the Regeneration Underway indicator above the words “HEST Lamp - Solid” when the unit is in the process of diesel exhaust filter regeneration. During the regeneration process, the exhaust temperature will be very high. DPF Status HEST Lamp - Solid DPF Lamp... -
Page 26: Belt Tensioners
General Information To reset the controller and resume operation, press the Enter () button. BELT TENSIONERS John Deere engines use two types of belt tensioners: manual and automatic. Adjust the belt using the manual tensioner according to the manufacturer’s specifications. The automatic tensioner cannot be adjusted or repaired and is designed to maintain proper tension over the belt’s life. -
Page 27: To Close The Front Hood
General Information 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. Failure to close the hood correctly could result in personal injury and equipment damage. - Page 28 General Information This Page Intentionally Left Blank MMG75D-100D Operating Manual 33701 C...
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Page 29: Section 3 - Operation
Section 3 - Operation PRESTART CHECKLIST Before starting the unit, all items in the prestart checklist must be completed. This checklist applies to both manual and remote starting of the unit. Read and understand ALL safety sections at the beginning of this manual. ... -
Page 30: Auto (Remote) Starting The Unit
Operation When the software is loaded, the Home screen will be displayed and the controller will be in Stop mode as indicated at the top of the screen. Press the Auto/Manual Mode ( ) button to enter Manual mode. Stop Mode Time to Empty 15 hr 100 110... -
Page 31: Transfer Switch
Operation and review all information on isolating the generator with a transfer switch if the unit is to be used as a standby power supply. See Auto Exercise Timer, then continue with the steps described below: 1. Perform a manual start of the unit at least once to verify that the engine is operating correctly. If a check of the remote start circuit is desired, remove the wires from the remote start terminal block. -
Page 32: Derating For Altitude
Operation Emergency Incoming Distribution Panel Utility (Generator Power) Power Main WHITE = Incoming Distribution Panel Utility Power (Utility Power) Utility GRAY = Normal Utility Meter Power Circuit Transfer Switch BLACK = Emergency Generator Power Circuit Power From Generator 00206 Figure 3-4. Transfer Switch Operation DANGER FAILURE TO ISOLATE THE GENERATOR FROM THE NORMAL POWER UTILITY CAN CAUSE POTENTIALLY LETHAL VOLTAGE TO BACKFEED INTO THE UTILITY LINES. -
Page 33: Generator Output Connections
Operation GENERATOR OUTPUT CONNECTIONS The unit is equipped with connection lugs, located on the lower portion of the control box behind the lug box door. 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 34: Voltage Selector Switch
Operation Manual Mode Voltage Adjust - Press , voltage will begin flashing - Use arrows to adjust voltage - Press to confirm new voltage. Numbers will stop flashing L-N Average L-L Average 00396 Figure 3-6. Voltage Adjust Screen 1. With the unit running, press Press . -
Page 35: Voltage Regulator
Operation 277/480V 3-PHASE L1-L2 = 480V L1-N = 277V 120/ 208V L2-L3 = 480V L2-N = 277V L3-L1 = 480V L3-N = 277V 277/ VOLTAGES AT RECEPTACLES 480V RECEPTACLE GFCI 139V GFCI w/Buck 120V Twist-locks 240V 139V Switch styles vary by model. 00083 = Not recommended for normal use 120/240V 3-PHASE... -
Page 36: Customer Convenience Receptacles
Operation CUSTOMER CONVENIENCE RECEPTACLES The unit is equipped with five receptacles. The 240/ 50A Circuit 20A Circuit 120VAC twist-lock receptacles are rated at 50A each. Breakers Breakers The 120VAC duplex receptacles are rated at 20A each, with ground fault circuit interrupt (GFCI) protec- tion. -
Page 37: Exhaust Filter Cleaning Operations
Operation Make sure any problems that cause the main circuit breaker to trip are corrected before returning the switch to ON (I). The main circuit breaker interrupts power to the connection lugs and the optional cam lock receptacles only. The customer convenience receptacles have power even if the main circuit breaker is OFF (O). -
Page 38: Enable Exhaust Filter Cleaning
Operation Enter the DPF Status screen and verify the Regeneration indicator appears above the words “DPF Lamp - Solid.” For information regarding the DPF Status screen and indicators, see Diesel Exhaust Filter Moni- toring. Enable Exhaust Filter Cleaning If the environment no longer requires the function to be disabled and there are no alarms present on the DPF Status screen, the auto exhaust filter cleaning function should be enabled. -
Page 39: Set The Unit To Auto Mode
Operation 1. Access the Scheduler group by pressing the ► button. Note: The Scheduler group is made up of the Scheduler Options and Scheduler Setup sections. Each section can be accessed and exited using the ► and ◄ buttons. Access the Scheduler Options section. Within this section, the scheduler can be enabled, run mode selected, and load mode selected. -
Page 40: Emergency Stop Switch
Operation After the unit shuts down, move the Control Power switch to OFF (O). Note: For extended storage time, disconnect the battery. See the engine operator’s manual for extended storage requirements. EMERGENCY STOP SWITCH The unit is equipped with one emergency stop switch. For location of the emergency stop switch, see Component Locations. -
Page 41: Lifting The Unit
Operation Verify all doors and hoods are properly latched. Check for proper inflation of the trailer tires. For maximum tire pressures, see Specifications. Check the wheel lugs. Tighten or replace any lugs 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. - Page 42 Operation This Page Intentionally Left Blank MMG75D-100D Operating Manual 33701 C...
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Page 43: Section 4 - Maintenance
Section 4 - Maintenance EMISSIONS INFORMATION For emissions information, see the OEM engine manual. DAILY WALK AROUND INSPECTION Look for conditions that could hinder performance or safety, such as (but not limited to) oil/coolant/fuel leakage, blocked vents, loose/missing hardware, and electrical connections. Visually inspect the fan belt for cracks, fraying, stretching, and verify the belt is properly seated in the pulley grooves. -
Page 44: Basic Maintenance Schedule
Maintenance • Verify the oil level daily. See the engine operator’s manual for the proper viscosity grade of oil, including special operating conditions such as a change in season or climate. ○ DO NOT start the unit if the engine oil level is below the add mark on the dipstick. ○... -
Page 45: Engine Break-In Requirements
Maintenance Table 4: Basic Maintenance Schedule Every Hrs. Every Every Every (Break- 3000 Item Daily Hrs./12 1000 Require Hrs./36 Hrs. Month Hrs. Period Months Only) Check Automatic Belt Tensioner and Belt Wear Check Cooling System Lubricate Leveling Jack(s) ... -
Page 46: Exhaust Filter Service Requirements
Maintenance Press to move the cursor (blue highlighted text) down to the Maintenance group. Press ► to access the sections. Press to highlight the Maintenance section. Press ► to access the parameters and highlight the maintenance alarm that needs to be reset. Press ... -
Page 47: Jack Maintenance
Maintenance Torque each of the drive plate bolts to the appropriate specification shown in the table below. Table 5: Drive Plate Bolt Torques Unit ft-lbs (Nm) MMG75D 36 (49) MMG100D 36 (49) Install generator fan guard. Connect battery. JACK MAINTENANCE The following procedures should be performed annually. - Page 48 Maintenance This Page Intentionally Left Blank MMG75D-100D Operating Manual 33701 C...
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Page 49: Section 5 - Troubleshooting
Section 5 - Troubleshooting GENERAL TROUBLESHOOTING This information is intended to be a check or verification for simple causes that can be located and fixed. It does not cover all types of problems. See the engine operator’s manual for additional troubleshooting information. Procedures that require in-depth knowledge or skills should be referred to a trained technician. - Page 50 Troubleshooting This Page Intentionally Left Blank MMG75D-100D Operating Manual 33701 C...
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Page 51: Section 6 - Wiring Diagrams
Section 6 - Wiring Diagrams AC WIRING - 3 POSITION VOLTAGE SELECTOR SWITCH 120V 120V MECHANICAL LUGS GFCI GFCI RECPT RECPT 120V 120V BRKER BRKER GROUND GRN/YEL TO GEN FRAME GRN/YEL GRN/YEL GRN/YEL GRN/YEL MAIN CIRCUIT BREAKER 240V WIRES NOT USED IN 240V 50A BUCK BOOST OPTION BREAKER... -
Page 52: Ac Wiring - 4 Position Voltage Selector Switch Option
Wiring Diagrams AC WIRING - 4 POSITION VOLTAGE SELECTOR SWITCH OPTION MECHANICAL LUGS 20 AMP 20 AMP G.F.I. G.F.I. 20 AMP 20 AMP OUTLET OUTLET GRN/YEL 14GA GRN/YEL 14GA GRN/YEL 10GA GRN/YEL 10GA CIRCUIT GRN/YEL 10GA GROUND BREAKER TO GEN FRAME CIRCUIT CIRCUIT CIRCUIT... -
Page 53: Ac Wiring Options
Wiring Diagrams AC WIRING OPTIONS 90415_T_06.17.15 33701 C MMG75D-100D Operating Manual... -
Page 54: Pmg Wiring Option
Wiring Diagrams PMG WIRING OPTION 90672_ORG_06.19.15 MMG75D-100D Operating Manual 33701 C... -
Page 55: Dc Wiring
Wiring Diagrams DC WIRING 90438_H_11.02.15 33701 C MMG75D-100D Operating Manual... -
Page 56: Dc Wiring Options
Wiring Diagrams DC WIRING OPTIONS 90416_N_11.20.14 MMG75D-100D Operating Manual 33701 C... -
Page 57: Low Oil Level Wiring Option
Wiring Diagrams LOW OIL LEVEL WIRING OPTION CONN-2 CONN-2 DEUTSCH DEUTSCH 21 PIN 31 PIN SWITCH CONTROLLER PIN 66 (7310) WT/BL WT/BL SPLICE CONTROLLER PIN 68 (PZ) CONN-2 CONN-2 DEUTSCH DEUTSCH 21 PIN 31 PIN BK/WT BK/WT 90611_ORG_12.03.14 BATTERY CHARGER WIRING OPTION EDISON PLUG YEL/GRN 16/3... -
Page 58: Wiring Block Diagram - Dedicated 12 Lead Generators Option
Wiring Diagrams WIRING BLOCK DIAGRAM - DEDICATED 12 LEAD GENERATORS OPTION 90302_A_11.06.12 MMG75D-100D Operating Manual 33701 C... -
Page 59: Trailer Lights Wiring
Wiring Diagrams TRAILER LIGHTS WIRING TRAILER PLUG TRAILER PLUG AMBER AMBER MARKER MARKER LAMP LAMP MARKER MARKER LAMP LAMP WHITE MARKER LAMP STOP-TURN STOP-TURN SIGNAL LAMP SIGNAL LAMP (LEFT) (RIGHT) 90431_ORG_09.11.12 33701 C MMG75D-100D Operating Manual... -
Page 60: Wiring Harness - Electric Brake Option
Wiring Diagrams WIRING HARNESS - ELECTRIC BRAKE OPTION 90286_E_03.18.14 MMG75D-100D Operating Manual 33701 C... -
Page 61: Section 7 - Options & Accessories
Section 7 - Options & Accessories VISCOUS FAN CLUTCH OPTION The viscous (cooling) fan clutch option allows the engine cooling fan to engage at lower speeds and disengage at higher speeds, increasing cooling system efficiency. The cooling fan will engage at full speed when the coolant temperature rises. - Page 62 Options & Accessories A ground connection is located on the far right of the cam lock panel. The unit MUST be connected to ground for proper operating safety. The generator neutral is bonded to ground when it is shipped from the factory. The bonding plate will need to be removed when the generator is used as a secondary power source or where bonding is completed elsewhere in the circuit.
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Page 63: Service Log
Service Log OIL GRADE: _____________________________________ BRAND: __________________________________ COOLANT MIXTURE: _____________________________ BRAND: __________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ Hours to Coolant Hours to Coolant Date Oil Level Date Oil Level Service Level Service Level... - Page 64 Notes ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________...
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