Generac Power Systems MAGNUM MGG200 Manual
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Generac Power Systems MAGNUM MGG200 Manual

Generac Power Systems MAGNUM MGG200 Manual

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GASEOUS GENERATOR
MGG200 • MGG200G
01913
PARTS MANUAL
38108 ORG 12/15

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  • Page 1 GASEOUS GENERATOR MGG200 • MGG200G 01913 PARTS MANUAL 38108 ORG 12/15...
  • Page 2 WARNING CALIFORNIA PROPOSITION 65 WARNING: Engine exhaust and some of its constitu- ents are known to the state of California to cause cancer, birth defects, and other reproductive harm. 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

    Introduction This parts manual was prepared based on the information available at the time of publication and is subject to change without notice. Generac Mobile Products reserves the right to change parts at any time. To check whether a revised parts manual is available, contact Generac Mobile Products.
  • Page 4 This Page Intentionally Left Blank...

  • Page 5: Table Of Contents

    Table of Contents Introduction .............................. iii Parts Manual Instructions......................1 Enclosure Panels........................2 Unit Decals - Exterior......................4 Unit Decals - Left Side Interior....................6 Unit Decals - Right Side Interior ................... 8 Unit Decals - Disconnect Box ..................... 10 Front and Rear Panels to Unit ....................
  • Page 6 This Page Intentionally Left Blank...

  • Page 7: Parts Manual Instructions

    Parts Manual Instructions Product illustrations are only representations. Products supplied may vary from the illustrations in this parts manual. Parts not shown in the illustration are indicated by a double dash (--) in the item column. Please be prepared to provide the following information when ordering replacement parts: model number, serial number (on unit serial tag), part number, purchase order number (if applicable), shipping address, shipping method.

  • Page 8: Enclosure Panels

    ENCLOSURE PANELS 01915 MGG200/200G Parts Manual 38108 ORG...
  • Page 9 ENCLOSURE PANELS Item Part No. Description Notes Page 28 Cover, exhaust bay MGG200 only Page 28 Duct, exhaust - top MGG200G only Page 32 Roof - front Page 32 Roof - rear Page 22 Door, solid - right w/manual holder Page 18 Door, solid - left Page 26...

  • Page 10: Unit Decals - Exterior

    UNIT DECALS - EXTERIOR WARNING WARNUNG ADVERTENCIA AVERTISSEMENT MAINTENANCE CHECKS Critical Daily Checks Verify trailer is as level as possible with tires blocked and jacks extended. Check tire pressure. Verify radiator and exhaust areas are clear of debris. Ensure the engine oil reservoir valve is open to allow oil to flow to the oil make-up controller.
  • Page 11 UNIT DECALS - EXTERIOR Item Part No. Description Notes 38450 Decal set, safety 34784 Decal, gaseous genset - 28.0 x 13.60 MGG200G only 37600 Decal, maintenance 36610 Decal, mobile - 200 38108 ORG MGG200/200G Parts Manual...

  • Page 12: Unit Decals - Left Side Interior

    UNIT DECALS - LEFT SIDE INTERIOR Read and understand the supplied operator’s manual before operating this machine. Failure to do so increases the risk of injury to yourself or others. Operator’s manual must be stored on machine. Replacement Vor dem Betrieb dieser Maschine muss das Bedienerhandbuch operator’s manual can be ordered through your local Magnum distributor.
  • Page 13 UNIT DECALS - LEFT SIDE INTERIOR Item Part No. Description Notes 38450 Decal set, safety 12142 Decal, ground 36609 Decal, caution - heat cable 38108 ORG MGG200/200G Parts Manual...

  • Page 14: Unit Decals - Right Side Interior

    UNIT DECALS - RIGHT SIDE INTERIOR WARNING NOTICE Close oil reservoir supply valve before HINWEIS WARNUNG transporting unit. If left AVISO ADVERTENCIA open, oil will overfill L1 L2 L3 the crankcase. AVIS AVERTISSEMENT 01918 MGG200/200G Parts Manual 38108 ORG...
  • Page 15 UNIT DECALS - RIGHT SIDE INTERIOR Item Part No. Description Notes 38450 Decal set, safety 38108 ORG MGG200/200G Parts Manual...

  • Page 16: Unit Decals - Disconnect Box

    UNIT DECALS - DISCONNECT BOX 01919 MGG200/200G Parts Manual 38108 ORG...
  • Page 17 UNIT DECALS - DISCONNECT BOX Item Part No. Description Notes 38450 Decal set, safety 12142 Decal, ground 38108 ORG MGG200/200G Parts Manual...
  • Page 18 ROOF AND DOORS TO UNIT 01920 MGG200/200G Parts Manual 38108 ORG...
  • Page 19 ROOF AND DOORS TO UNIT Item Part No. Description Notes Page 32 Assembly, roof 60024 Screw, M6-1.0 x 25 sflg hex 39635 Screw, M8-1.250 x 16 button hex, SS Page 20 Assembly, solid door - right Page 18 Assembly, solid door - left Page 26 Assembly, louvered door - right Page 24...

  • Page 20: Front And Rear Panels To Unit

    FRONT AND REAR PANELS TO UNIT 01921 MGG200/200G Parts Manual 38108 ORG...
  • Page 21 FRONT AND REAR PANELS TO UNIT Item Part No. Description Notes 63158 Insert, M8-1.250 39611 Corner post, front - left 39612 Block off, top 60024 Screw, M6-1.0 x 25 sflg hex 39613 Block off, bottom 39610 Corner post, front - right Page 34 Assembly, rear corner post - right 39607...

  • Page 22: Center Panels To Unit

    CENTER PANELS TO UNIT 01922 MGG200/200G Parts Manual 38108 ORG...
  • Page 23 CENTER PANELS TO UNIT Item Part No. Description Notes 39608 Side brace, top and bottom 63158 Insert, M8-1.250 39609 Support, center door 60024 Screw, M6-1.0 x 25 sflg hex 38108 ORG MGG200/200G Parts Manual...

  • Page 24: Door Assembly - Left

    DOOR ASSEMBLY - LEFT 01924 MGG200/200G Parts Manual 38108 ORG...
  • Page 25 DOOR ASSEMBLY - LEFT Item Part No. Description Notes 39640 Nut,.250-20 nylock 39356 Washer, .250-M6 flat 39632 Roller rod, T-handle 39419 Nut, M6-1.0 hex, G8 38522 Washer, M6-.250 split lock 39631 Bracket, rod guide 39628 Door, solid - left 39639 Nut, M4-.70 nylock, SS 39593 Washer, #8 flat, SS...

  • Page 26: Door Assembly - Right

    DOOR ASSEMBLY - RIGHT 01925 MGG200/200G Parts Manual 38108 ORG...
  • Page 27 DOOR ASSEMBLY - RIGHT Item Part No. Description Notes 39629 Door, solid - right 63158 Insert, M8-1.250 39624 Hinge, M8 top - right 39635 Screw, M8-1.250 x 16 button hex, SS 53470 Hinge, M8 bottom - right 38108 ORG MGG200/200G Parts Manual...

  • Page 28: Door Assembly - Right (With Manual Holder)

    DOOR ASSEMBLY - RIGHT (WITH MANUAL HOLDER) 01926 MGG200/200G Parts Manual 38108 ORG...
  • Page 29 DOOR ASSEMBLY - RIGHT (WITH MANUAL HOLDER) Item Part No. Description Notes 39629 Door, solid - right 63158 Insert, M8-1.250 39624 Hinge, M8 top - right 39635 Screw, M8-1.250 x 16 button hex, SS 53470 Hinge, M8 bottom - right 24540 Holder, manual 60067...

  • Page 30: Door Assembly - Louvered - Left

    DOOR ASSEMBLY - LOUVERED - LEFT 01927 MGG200/200G Parts Manual 38108 ORG...
  • Page 31 DOOR ASSEMBLY - LOUVERED - LEFT Item Part No. Description Notes 39640 Nut,.250-20 nylock 39356 Washer, .250-M6 flat 39632 Roller rod, T-handle 39419 Nut, M6-1.0 hex, G8 38522 Washer, M6-.250 split lock 39631 Bracket, rod guide 39626 Door, louvered - left 39639 Nut, M4-.70 nylock, SS 39593...

  • Page 32: Door Assembly - Louvered - Right

    DOOR ASSEMBLY - LOUVERED - RIGHT 01928 MGG200/200G Parts Manual 38108 ORG...
  • Page 33 DOOR ASSEMBLY - LOUVERED - RIGHT Item Part No. Description Notes 39627 Door, louvered - right 63158 Insert, M8-1.250 39624 Hinge, M8 top - right 39635 Screw, M8-1.250 x 16 button hex, SS 53470 Hinge, M8 bottom - right 38108 ORG MGG200/200G Parts Manual...

  • Page 34: Front Enclosure Assembly

    FRONT ENCLOSURE ASSEMBLY 01929 MGG200/200G Parts Manual 38108 ORG...
  • Page 35 FRONT ENCLOSURE ASSEMBLY Item Part No. Description Notes 35105WG Cover, exhaust bay MGG200 only 38523 Duct, front top left MGG200G only 60024 Screw, M6-1.0 x 25 sflg hex 39345 Washer, .312 flat 38382 Washer, .312 split lock 38383 Screw, M8-1.250 x 20 hex, G8.8 39617 Duct, front left 39619...

  • Page 36: Catalyst Door Assembly

    CATALYST DOOR ASSEMBLY 01930 MGG200/200G Parts Manual 38108 ORG...
  • Page 37 CATALYST DOOR ASSEMBLY Item Part No. Description Notes 60095 Nut, .312-18 sflg hex 35041WG Spacer, catalyst door hinge 18461 Hinge, left - male 61066 Screw, .312-18 x 1.0 carriage, SS 18460 Hinge, left - female 60268 Rivet, .188 dia x .126 to .250 grip 22498 Latch, T-handle - right ccw lock 35042WG...

  • Page 38: Roof Assembly

    ROOF ASSEMBLY 01931 MGG200/200G Parts Manual 38108 ORG...
  • Page 39 ROOF ASSEMBLY Item Part No. Description Notes 60527 Washer, .750 flat 1.50/.125, hardened 60532 Screw, .750-10 x 3.0 hex, G8 18053B Bracket, lift eye 60024 Screw, M6-1.0 x 25 sflg hex 31823B Spacer, lift plate 60248 Washer, .750 split lock 60249 Nut, .750-10 hex, G8 53276...

  • Page 40: Rear Corner Assembly - Right

    REAR CORNER ASSEMBLY - RIGHT 01932 MGG200/200G Parts Manual 38108 ORG...
  • Page 41 REAR CORNER ASSEMBLY - RIGHT Item Part No. Description Notes 39606 Corner post, rear - right 60260 Rivet, .188 dia x .375 to .500 grip 65470 Switch, E-stop operator 30645 Panel, E-stop 65471 Block, E-stop contactor - N.O. 65472 Block, E-stop contactor - N.C./N.O. 31779 Assembly, E-stop 38108 ORG...

  • Page 42: Control Boxes And Lift Structure To Unit

    CONTROL BOXES AND LIFT STRUCTURE TO UNIT 01933 MGG200/200G Parts Manual 38108 ORG...
  • Page 43 CONTROL BOXES AND LIFT STRUCTURE TO UNIT Item Part No. Description Notes Page 42 Assembly, lift structure 39345 Washer, .312 flat 38382 Washer, M8-312 split lock 38383 Screw, M8-1.25 x 20 hex, G8.8 Page 40 Assembly, connection box 39427 Screw, .312-18 x .75 hex Page 38 Assembly, control box Page 70...

  • Page 44: Control Box Assembly

    CONTROL BOX ASSEMBLY 01934 MGG200/200G Parts Manual 38108 ORG...
  • Page 45 CONTROL BOX ASSEMBLY Item Part No. Description Notes 36758 H-panel, programmed 39478 Cover, customer connection H-panel 39477 Block, terminal, 20A, 8 x 6 x 1100V 39459 Block, terminal, 20A, 12 x 6 x 1100V 53280 Screw, M4-.70 x 16 pan phil 39478 Cover, customer connect - H-panel 60024...

  • Page 46: Connection Box Assembly

    CONNECTION BOX ASSEMBLY 01935 MGG200/200G Parts Manual 38108 ORG...
  • Page 47 CONNECTION BOX ASSEMBLY Item Part No. Description Notes 39421 Funnel, wire 60024 Screw, M6-1.0 x 25 sflg hex 39430 Plug, 1.50 plastic 39412 Cover, MD3 module 39418 Screw, M6-1.0 x 45, G12.9 53353 Breaker, Eaton K-frame 39413 Bracket, circuit breaker 39345 Washer, .312 flat 38522...

  • Page 48: Disconnect Box Assembly

    DISCONNECT BOX ASSEMBLY 01937 MGG200/200G Parts Manual 38108 ORG...
  • Page 49 DISCONNECT BOX ASSEMBLY Item Part No. Description Notes 31014 Box, disconnect switch, 400A, 600V AC/DC 34507 Fitting, pipe nipple - 3.0NPT x 8.0, black pipe 62221 Nut, .500-13 nylock, G5 60309 Washer, .500 flat - 1.060/.090 63186 Screw, .500-13 x 1.250 std hex, G5 19351 .833 ft Seal, U-channel...

  • Page 50: Lift Structure Assembly

    LIFT STRUCTURE ASSEMBLY To Battery 01936 MGG200/200G Parts Manual 38108 ORG...
  • Page 51 LIFT STRUCTURE ASSEMBLY Item Part No. Description Notes 34766B Cross member, lift structure 60668 Nut, .500-13 nylock 60670 Washer, .500 flat 1.060/.110, G8 60118 Screw,.500-13 x 2.0 flg hex, G8 34767B Side member, lift structure 60095 Nut, .312-18 sflg 60516 Screw, .312-18 x 1.25 sflg hex 34536 Cable, battery - 12 in.

  • Page 52: Exhaust System Assembly

    EXHAUST SYSTEM ASSEMBLY 01938 MGG200/200G Parts Manual 38108 ORG...
  • Page 53 EXHAUST SYSTEM ASSEMBLY Item Part No. Description Notes 34727 Pipe, exhaust - catalyst, G20 34946 Clamp, band - 4.0 in 34618 Pipe, flex - 4.0 in 34728 Pipe, exhaust - upper G20 39560 Screw, M10-1.5 x 25, SS 39559 Washer, M10 split lock, SS 39596 Stiffener, exhaust bracket - inner 39602...

  • Page 54: Cooling System Assembly

    COOLING SYSTEM ASSEMBLY 01939 MGG200/200G Parts Manual 38108 ORG...
  • Page 55 COOLING SYSTEM ASSEMBLY Item Part No. Description Notes 39529 Support, radiator - left 34630 Radiator, right hand in/out 34962 Cap, radiator - 20 PSI 34782B Guard, radiator screen 60027 Washer, M10-.375 flat 60346 Washer, M10 split lock 39344 Screw, M10-1.50 x 25, G8.8 39533 Support, radiator - right 34628...

  • Page 56: Cooling System Hoses

    COOLING SYSTEM HOSES 01940 MGG200/200G Parts Manual 38108 ORG...
  • Page 57 COOLING SYSTEM HOSES Item Part No. Description Notes 34955 Clamp, hose band .500 in 34961 Hose, .281 ID 35176 Sensor, coolant level .325-18NPTF 60087 Screw, M6-1 x 16 sflg hex 35863 Bracket, signal conditioner 53293 Clamp, .62 x .406 63111 Screw, .70-10 x 2.250 flg hex, G8 60527 Washer, .750 flat - 1.50/.125...

  • Page 58: Fuel Water Separator Assembly

    FUEL WATER SEPARATOR ASSEMBLY 01941 MGG200/200G Parts Manual 38108 ORG...
  • Page 59 FUEL WATER SEPARATOR ASSEMBLY Item Part No. Description Notes 31135 Fitting, 90° - 2.0NPT, black pipe 31010 Fitting, strt - 2.0MNPT x 2.0 barb 60666 Clamp, hose - constant torque 2.25 - 3.125 31040 8.37 ft Hose, fuel - 2.0 ID, 150 psi 60303 Nut, .312-18 nylock, G2 60119...

  • Page 60: Air Filter Assembly

    AIR FILTER ASSEMBLY 01942 MGG200/200G Parts Manual 38108 ORG...
  • Page 61 AIR FILTER ASSEMBLY Item Part No. Description Notes 39546 Clamp, 4.25 - 5.125 hi torque 39545 Tube, air intake w/beaded tube 39547 Plug, .125 std pipe - square head 39544 Clamp, 10.19 band 34554 Filter, air ECO-SE 39344 Screw, M10-1.5 x 25 hex, G8.8 60027 Washer, M10 - .375 flat 60026...

  • Page 62: Fuel System Assembly - 1 Of 2

    FUEL SYSTEM ASSEMBLY - 1 OF 2 01943 MGG200/200G Parts Manual 38108 ORG...
  • Page 63 FUEL SYSTEM ASSEMBLY - 1 OF 2 Item Part No. Description Notes 34933 Mixer, fuel - 400V side draft 39581 Gasket, carburetor mixer 39568 Screw, tamper-proof 60269 Washer, #8 flat .433/.036 39585 Cover, tamper-proof - 400VF mixer 39572 Pipe, turbo adapter 38382 Washer, M8-.312 lock 39583...

  • Page 64: Fuel System Assembly - 2 Of 2

    FUEL SYSTEM ASSEMBLY - 2 OF 2 01944 MGG200/200G Parts Manual 38108 ORG...
  • Page 65 FUEL SYSTEM ASSEMBLY - 2 OF 2 Item Part No. Description Notes 53309 Fitting, pipe nipple 1.250NPT x 1.625 - close 53310 Coupling, 1.250-1.50 - full 37350 Fitting, 90°- .312 x .250NPT barb 39565 Clamp, hose - SAE 5.5 (.62-.62) 34941 3.35 ft Hose, heater - .312 ID...

  • Page 66: Turbocharger Assembly

    TURBOCHARGER ASSEMBLY 01945 MGG200/200G Parts Manual 38108 ORG...
  • Page 67 TURBOCHARGER ASSEMBLY Item Part No. Description Notes 39556 Screw, M10-1.5 x 30 socket hex, G12.9 60026 Washer, M10 split lock 53362 Fitting, 90° JIC-NPT 53363 Adapter, oil inlet flange, 39550 Gasket, oil inlet flange 53364 Nut, M10-1.5 hex, SS 53365 Shield, heat - turbo rear 53366 Washer, M10 split lock, SS...

  • Page 68: Engine And Generator To Unit

    ENGINE AND GENERATOR TO UNIT 01946 MGG200/200G Parts Manual 38108 ORG...
  • Page 69 ENGINE AND GENERATOR TO UNIT Item Part No. Description Notes 53323 Screw, M14-2.0 x 110, G8.8 53324 Washer, .562 flat 34904 Mount, vibro - upper 34903 Mount, vibro - lower 53327 Nut, M14-2.0 nylock 38920 J-bolt, .250-20 x 12.0, long 38919 Bracket, battery tie down 35910...

  • Page 70: Engine Assembly - Left Side

    ENGINE ASSEMBLY - LEFT SIDE Engine To Oil Tank To Oil Pan 01947 MGG200/200G Parts Manual 38108 ORG...
  • Page 71 ENGINE ASSEMBLY - LEFT SIDE Item Part No. Description Notes 39510 Pipe, oil fill Reuse hardware 34907 Cap, oil 53331 Fitting, 90° - .375NPT x .625 barb 34905 Clamp, hose .875 double wire 35380 6.83 ft Hose, .625 ID, SAE 20R3 35380 2.1 ft Hose, .625 ID, SAE 20R3...

  • Page 72: Engine Assembly - Right Side

    ENGINE ASSEMBLY - RIGHT SIDE To skid 01948 MGG200/200G Parts Manual 38108 ORG...
  • Page 73 ENGINE ASSEMBLY - RIGHT SIDE Item Part No. Description Notes 37863 Dispenser, grease MGG200G only 37866 Fitting, .125NPT coupler - thru wall MGG200G only 37864B Bracket, grease dispenser MGG200G only 60451 Screw, .375-16 x .625 flg hex MGG200G only 37865 Hose, .125NPT, grease gun MGG200G only 38288...

  • Page 74: Generator Assembly

    GENERATOR ASSEMBLY 01949 MGG200/200G Parts Manual 38108 ORG...
  • Page 75 GENERATOR ASSEMBLY Item Part No. Description Notes 60024 Screw, M6-1.0 x 25 sflg hex 39385 Top, alternator tower - LH module 39389 Cover, alternator tower 39406 Screw, M8-1.25 x 16, G8.8 39345 Washer, .312 flat 39390 Transformer, current - 50A w/bracket 39384 Main, alternator tower 39405...

  • Page 76: Skid Assembly

    SKID ASSEMBLY 01950 MGG200/200G Parts Manual 38108 ORG...
  • Page 77 SKID ASSEMBLY Item Part No. Description Notes 39485 Weldment, skid 60033 Nut, M10-1.5 sflg hex, G8.8 39424 Washer, .375 special lock 39423 Lug, 3/0 - #4 x .406 60027 Washer, M10-.375 flat 39344 Screw, M10-1.5 x 25 hex, G8.8 60994 Screw, .625-11 x 1.50 flg hex, G8 30864B Pan, drip...

  • Page 78: Trailer Assembly

    TRAILER ASSEMBLY 01951 MGG200/200G Parts Manual 38108 ORG...
  • Page 79 TRAILER ASSEMBLY Item Part No. Description Notes 61103 Screw, .500-13 x 1.75 sflg hex 66397 Light, clearance 2.00 in. - red 66394 Grommet, sealed beam light - rubber 2.00 in 61091 Screw, .312-18 x 1.0 sflg hex, G5 27657B Weldment, fender 22398 Pad, slip resistant 10.0 x 28.0 26877B...

  • Page 80: Axle Assembly

    AXLE ASSEMBLY 00259 MGG200/200G Parts Manual 38108 ORG...
  • Page 81 AXLE ASSEMBLY Item Part No. Description Notes 22145 Axle, 6000 lb. - 57 in. frame Hydraulic brake 26571 Surge free-backing brake - left 26572 Surge free-backing brake - right 26575 Inner grease seal 2.125 in 26576 Inner hub bearing 26577 Inner bearing cup 22387 Drum, large trailer brake...

  • Page 82: Trailer Brake Lines

    TRAILER BRAKE LINES 00618 MGG200/200G Parts Manual 38108 ORG...
  • Page 83 TRAILER BRAKE LINES Item Part No. Description Notes 40495 Line, brake - .188 x 20.0 60684 Screw, .250-20 x .875 std. hex, SS 19252 Fitting, strt - .188 brake line T w/bracket - female 60144 Nut, .250-20 nylock, G5 22338 Line, brake - .188 x 60.0 22339 Fitting, strt - .188 brake line coupler...

  • Page 84: Trailer Hitch Options

    TRAILER HITCH OPTIONS 00619 MGG200/200G Parts Manual 38108 ORG...
  • Page 85 TRAILER HITCH OPTIONS Item Part No. Description Notes 62221 Nut, .500-13 nylock, G5 60309 Washer, .500 flat 1.060/.090 18373 Actuator, trailer 60376 Screw, .500-13 x 4.50 std hex, G5 60239 Screw, .625-11 x 5.0 std hex, G5 60193 Washer, M16 flat 60240 Nut, .625-11 nylock, G5 19335B...

  • Page 86: Recommended Spare Parts List

    RECOMMENDED SPARE PARTS LIST ENGINE Alternator ......................34546 AVR........................34892 Belt, fan ......................34619 Cap, radiator ....................34962 Dipstick ......................53338 Element, air filter....................53303 EPR valve......................35617 Fan ........................30461 Filter, oil ......................34553 Filter, LP ......................31318 Gasket set ......................35554 Hose, radiator - lower ..................

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