Related Manuals for Generac Power Systems Magnum Series
Summary of Contents for Generac Power Systems Magnum Series
- Page 1 DIESEL GENERATOR MMG130DI4 • MMG175DI4 • MMG205DI4 With Controller 02068 OPERATING MANUAL Parts manuals available online at www.generacmobile.com 33722 D 01/16...
- 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.
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Page 3: Introduction
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. - Page 4 This Page Intentionally Left Blank...
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Page 5: Table Of Contents
Table of Contents Introduction ..........................iii 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 Voltage Regulator..........................30 Customer Convenience Receptacles ....................30 Main Circuit Breaker ......................... 31 Exhaust Filter Cleaning Operations....................31 Transfer Switch..........................31 Auto Exercise Timer ......................... 33 Accessing the Configuration Menu ..................33 Set the Controller Clock....................... 33 Set the Schedule ......................... 33 Set the Unit To Auto Mode ....................
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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 MMG130DI4 MMG130DI4 Super Start Engine Make/Brand................John Deere......John Deere Model ..................PE4045HFG93 ......PE4045HFG93 EPA Tier ..................F4 ..........F4 Horsepower - Prime hp (kW) ..........152 (113) .........152 (113) Horsepower - Standby hp (kW) ..........166 (124) .........166 (124) Operating Speed rpm .............1800 ........1800 Displacement in (L) ..............275 (4.5) ........275 (4.5) - Page 12 General Information GENERAC MODEL MMG175DI4 MMG175DI4 Super Start Engine Make/Brand................John Deere......John Deere Model ..................PE6068HFG94 ......PE6068HFG94 EPA Tier ..................4i ..........4i Horsepower - Prime hp (kW) ..........217 (162) .........217 (162) Horsepower - Standby hp (kW) ..........241 (180) .........241 (180) Operating Speed rpm .............1800 ........1800 Displacement in (L) ..............415 (6.8) ........415 (6.8) Cylinders - qty .................6 ..........6...
- Page 13 General Information GENERAC MODEL MMG205DI4 MMG205DI4 Super Start Engine Make/Brand................John Deere......John Deere Model ..................PE6068HFG95 ......PE6068HFG95 EPA Tier ..................4i ..........4i Horsepower - Prime hp (kW) ..........252 (188) .........252 (188) Horsepower - Standby hp (kW) ..........268 (200) .........268 (200) Operating Speed rpm .............1800 ........1800 Displacement in (L) ..............415 (6.8) ........415 (6.8) Cylinders - qty .................6 ..........6...
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Page 14: Unit Dimensions
General Information Unit Dimensions 02069 Figure 2-1. Unit Dimensions MMG130 DI4 /175 DI4 /205 DI4 - 50 in. (1.27 m) 77 in. (1.96 m) 144 in. (3.66 m) Skid Mounted MMG130 DI4 /175 DI4 /205 DI4 - 86 in. (2.18 m) 93 in. -
Page 15: Unit Serial Number Locations
GONF A FROID - KPA(PSI/LPC) SGL / DUAL Manufactured by Generac Mobile Products, LLC., The weight of cargo should never exceed 0000KG (0000LBS) a subsidiary of Generac Power Systems, Inc. Le poids du chargement ne doit jamais depasser 0000KG (0000LBS) (920) 361-4442... -
Page 16: Component Locations
General Information COMPONENT LOCATIONS 02112 Figure 2-3. Component Locations 1. Central lift point 7. Radiator access panel 2. Voltage selector access 8. Engine exhaust 3. Fuel fill 9. Radiator drain port 4. Engine battery access 10. Oil drain port 5. Ladder 11. -
Page 17: Control Panel
General Information CONTROL PANEL 00387 Figure 2-4. Control Panel Component Locations 1. Document holder 9. 120/240V twist-lock receptacles (3) 10. Connection for engine block heater 2. Power Zone™ controller (optional) 3. Auxiliary light switches (2) (optional) 11. Door safety switch 4. -
Page 18: Control Panel - With Cam Lock Option
General Information CONTROL PANEL - WITH CAM LOCK OPTION 00388 Figure 2-5. Control Panel Component Locations 1. Document holder 9. 120/240V twist-lock receptacles (3) 10. Connection for engine block heater 2. Power Zone™ controller (optional) 3. Auxiliary light switches (2) (optional) 11. -
Page 19: Power Zone™ Controller
General Information POWER ZONE™ 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 20: Auto/Manual Mode
General Information Auto/Manual Mode 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: Engine Screen
General Information unit management software is loaded. It displays a live readout of the kW meter, percent of load used (gauge), selected phase, volts and amps being produced by the generator, and the fuel level with time until empty. The controller will automatically return to this screen from any other screen after a period of inactivity. -
Page 22: Generator Screen
General Information • Battery: Displays the engine battery voltage. Current battery voltage is displayed directly below the gauge at all times. The gauge displays battery voltage between 0-50V. A normal reading is 12-14V on 12 volt systems and 24-26V on 24 volt systems (with the engine running). Generator Screen The Generator screen 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). -
Page 23: Maintenance Screens
General Information 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 2-10. Voltage Adjust Screen MAINTENANCE SCREENS All of the data inputs from the engine, generator, inputs/outputs, schedule and Power Zone™... -
Page 24: Generator Tab
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 0.00 °F Oil press. Coolant Temp. Fuel Level 0 0 0 0 0 0 0 Engine Starts Fuel Used US Gal °F Fuel Remaining... - Page 25 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 Warning Shutdown Electrical Trip Engine Engine Generator Alarms Schedule Status 00400 Figure 2-14. Alarms Tab Screen Color - Alarm Type Graphic Background/Text Warning...
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Page 26: Input/Output Tab
General Information To scroll down within the event log, press the Enter () button. The scroll bar will change to blue, signifying it is active. Press the ▲ or buttons to scroll up or down in the event log. When finished, press the Enter () button again. Input/Output Tab The Input/Output (I/O) tab shows a list of digital inputs and outputs connected to the controller, whether they are active and the current state (open/closed status) of the input and output. -
Page 27: Status Tab
General Information Status Tab The Status tab contains the status and configuration of the controller, firmware and data connections. SITE GENSET 7741 \ 7740 480V/277V 3-Phase 07:10 Return Delay 10:00:00 Total Generator kWh+ kVAr kVAh 0.00 kVAr kVArh Model Bootloader Model Application Analogue... -
Page 28: Power Zone™ Controller Information Displays, Functions, And Reset
General Information disabled, the indicator will begin to flash above the words “DPF Lamp -Flashing” if the soot load level goes above 80%. DPF Status DPF Status HEST Lamp DPF Lamp - Solid HEST Lamp DPF Lamp - Flashing DPF Inhib Alarm DPF Inhib Alarm... -
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 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...
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Page 31: Auto (Remote) Starting Of The Unit
Operation AUTO (REMOTE) STARTING OF THE UNIT Auto mode is used when the unit is started from a location other than the control panel by using a transfer switch. Auto (remote start) is the normal setting when the unit is being used as a standby power supply. Before putting the unit in the Auto mode, review the Prestart Checklist Manually Starting the... -
Page 32: Generator Cam Lock Connection(S) Option
Operation WARNING Before any connections are made to the generator, make sure that the main circuit breaker and the Control Power switch are OFF (O). Potentially lethal voltages may be present at the generator connection lugs. DANGER IMPROPER OR INCORRECT CONNECTIONS TO A BUILDING’S ELECTRICAL SYSTEM CAN CAUSE POTENTIALLY LETHAL VOLTAGES TO BACKFEED INTO UTILITY LINES. - Page 33 Operation DANGER IMPROPER OR INCORRECT CONNECTIONS TO A BUILDING’S ELECTRICAL SYSTEM 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.
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Page 34: Fine Voltage Adjustment
Operation FINE VOLTAGE ADJUSTMENT Adjustment of the output voltage from the generator is necessary to provide the correct voltage to the end of the power line. Voltage adjustment can be carried out at any time on the Voltage Adjust screen. Manual Mode Voltage Adjust - Press... - Page 35 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 Switch styles vary by model. Twist-locks 240V 139V 00083...
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Page 36: Voltage Regulator
Operation VOLTAGE REGULATOR The electronic voltage regulator controls the output of the generator by regulating the current into the exciter field. The regulator has four screwdriver adjustable potentiometers that may be adjusted for U/F dip, under frequency protection (U/F), stability, and voltage. The voltage regulator on the unit is adjusted before shipment from the factory. Contact Generac Mobile Products LLC for additional information before attempting to adjust the voltage regulator. -
Page 37: Main Circuit Breaker
Operation MAIN CIRCUIT BREAKER The main circuit breaker is located on the main control panel. When the breaker is OFF (O), power is interrupted between the connection lugs, the optional cam lock On/I On/I receptacles, and the generator. Once the connections have been made to the connection lugs or the optional cam lock receptacles, and the unit has been started and allowed to reach normal operating temperature, the breaker may be switched ON (I). - Page 38 Operation 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.
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Page 39: Auto Exercise Timer
Operation AUTO EXERCISE TIMER The Power Zone™ controller is capable of starting and stopping the unit automatically, based on a programmable schedule. Units installed in a standby application should be exercised regularly to maintain operating condition and to ensure responsiveness in an emergency situation. Use the following procedures to operate the unit in Auto mode: Accessing the Configuration Menu 1. -
Page 40: Set The Unit To Auto Mode
Operation Item Values Schedule Entry 1-16 Start Time 00:00-23:59 Duration 00:00-99:59 Monday-Sunday Week (of month) First, Second, Third, Fourth Note: The controller must be in Auto mode to run at the programmed time. Use a trickle or solar battery charger to prevent the controller from draining the battery while in Auto mode. -
Page 41: Towing The Unit
Operation Use the emergency stop switch only when the unit must be shut down immediately. For any other shut down, see Shutting Down the Unit. TOWING THE UNIT 1. Use the jack to raise or lower the trailer onto the hitch of the towing vehicle. Lock the hitch coupling and attach the safety chains or cables to the vehicle. - Page 42 Operation This Page Intentionally Left Blank MMG130DI4/175DI4/205DI4 Operating Manual 33722 D...
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Page 43: Section 4 - Maintenance
Section 4 - Maintenance EMISSIONS INFORMATION For emissions information, see the engine OEM 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 - John Deere Engine
Maintenance • Check 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 3000 Item Daily Hrs./12 Hrs./ 36 Hrs. Required Months Months Replace Air Cleaner Elements Replace Alternator and Fan Belts Check Fuses Add Coolant Check Electrical Wiring and Connections Replace primary air cleaner when dust valve restriction indicator gauge shows a vacuum of 25 in. H Change the oil and oil filter after the first 100 hours, then every 500 hours. -
Page 46: Exhaust Filter Service Requirements (For Pz Units With Dpf Only)
Maintenance To save changes, press and hold the Enter () button for five seconds. To discard changes made, press and hold the Engine Stop/Reset (O) button for five seconds. EXHAUST FILTER SERVICE REQUIREMENTS (FOR PZ UNITS WITH DPF ONLY) The exhaust filter system contains a Diesel Particulate Filter (DPF). Over time, the DPF will require professional servicing to remove ash buildup. -
Page 47: Top-Wind Models
Maintenance standard grease gun on the lubrication point found on the side of the jack near the crank. Rotate the jack handle to distribute the grease evenly. • A lightweight oil must be applied to the handle unit at both sides of the tube. •... - Page 48 Maintenance This Page Intentionally Left Blank MMG130DI4/175DI4/205DI4 Operating Manual 33722 D...
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Page 49: Section 5 - Troubleshooting
Section 5 - Troubleshooting GENERAL TROUBLESHOOTING Some of the more common problems are listed in the table below. This information is intended to be a check or verification that simple causes can be located and fixed. It does not cover all types of problems. Refer to the OEM engine operator’s manual for additional troubleshooting information. - Page 50 Troubleshooting Table 1 - General Troubleshooting Guide Problem Possible Cause Solution Check fuel level in tank. Check fuel pump operation. Overcrank Shutdown Fuel level low Check air filter for blockage. See the OEM engine operator’s manual for additional infor- mation. Disconnect all loads and restart unit.
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Page 51: Section 6 - Wiring Diagrams
Section 6 - Wiring Diagrams AC WIRING - 3 POSITION VOLTAGE SELECTOR SWITCH - MMG130DI4 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 WIRES NOT USED IN 240V 240V 50A BUCK BOOST OPTION... -
Page 52: Ac Wiring - 3 Position Voltage Selector Switch - Mmg175Di4
Wiring Diagrams AC WIRING - 3 POSITION VOLTAGE SELECTOR SWITCH - MMG175DI4 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 WIRES NOT USED IN 240V 240V 50A BUCK BOOST OPTION... -
Page 53: Ac Wiring - 3 Position Voltage Selector Switch - Mmg205Di4
Wiring Diagrams AC WIRING - 3 POSITION VOLTAGE SELECTOR SWITCH - MMG205DI4 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 WIRES NOT USED IN 240V 240V 50A BUCK BOOST OPTION... -
Page 54: Ac Wiring - 4 Position Voltage Selector Switch Option - Mmg130Di4, Mmg175Di4
Wiring Diagrams AC WIRING - 4 POSITION VOLTAGE SELECTOR SWITCH OPTION - MMG130DI4, MMG175DI4 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... -
Page 55: Ac Wiring - 4 Position Voltage Selector Switch Option - Mmg205Di4
Wiring Diagrams AC WIRING - 4 POSITION VOLTAGE SELECTOR SWITCH OPTION - MMG205DI4 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 BREAKER GROUND TO GEN FRAME CIRCUIT CIRCUIT... -
Page 56: Ac Wiring Options
Wiring Diagrams AC WIRING OPTIONS 90415_T_06.17.15 MMG130DI4/175DI4/205DI4 Operating Manual 33722 D... -
Page 57: Dc Wiring
Wiring Diagrams DC WIRING 90438_H_11.02.15 33722 D MMG130DI4/175DI4/205DI4 Operating Manual... -
Page 58: Dc Wiring Options
Wiring Diagrams DC WIRING OPTIONS 90416_N_11.20.14 MMG130DI4/175DI4/205DI4 Operating Manual 33722 D... -
Page 59: Wiring Block Diagram - Dedicated 12 Lead Generators Option
Wiring Diagrams WIRING BLOCK DIAGRAM - DEDICATED 12 LEAD GENERATORS OPTION 90302_A_11.06.12 33722 D MMG130DI4/175DI4/205DI4 Operating Manual... -
Page 60: Trailer Lights Wiring
Wiring Diagrams TRAILER LIGHTS WIRING 90386_A_02.14.14 MMG130DI4/175DI4/205DI4 Operating Manual 33722 D... -
Page 61: Wiring Harness - Electric Brake Option
Wiring Diagrams WIRING HARNESS - ELECTRIC BRAKE OPTION 90286_E_03.18.14 33722 D MMG130DI4/175DI4/205DI4 Operating Manual... - Page 62 Wiring Diagrams This Page Intentionally Left Blank MMG130DI4/175DI4/205DI4 Operating Manual 33722 D...
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Page 63: Section 7 - Options & Accessories
Section 7 - Options & Accessories GENERATOR CAM LOCK CONNECTIONS OPTION The unit may be equipped with cam lock connections, located below the receptacles. These receptacles provide connection points for the 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 64: Viscous Fan Clutch Option
Options & Accessories VISCOUS FAN CLUTCH OPTION The viscous 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 65 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 66 Notes ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________...
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