Free Generac MAGNUM MMG75CAN6 Operating Manual PDF | Manualsnet (2024)

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POWER PRODUCTS LLC

DIESEL GENERATOR

www m-p-llc com

MMG75CAN6 MMG100CAN6

OPERATING MANUAL

INTRODUCTION

This manual provides information and procedures to safely operate and maintain the engine and generator. For your own safety and protection from physical injury, carefully read, understand, and observe the safety instructions described in this manual. The information contained in this manual was based on machines in production at the time of publication. Magnum Power Products LLC reserves the right to change any portion of this information without notice.

DO NOT MODIFY or use this equipment for any application other than which it was designed for.

Magnum Power Products LLC recommends that a trained and licensed professional perform all electrical wiring and testing functions. Any wiring should be in compliance with the United States National Electric Code (NEC), state and local codes, and 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 Power Products LLC, or can be found at www.m-p-llc.com. An engine operators manual is supplied with the unit at the time of shipment from the factory. The manual provides detailed operation and maintenance procedures for the engine. Additional copies of the engine 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.com

For technical or parts QUESTIONS, please contact the Magnum Power Products LLC Customer Support or Technical Support team at 1-800-926-9768. Please have your serial number available.

To ORDER SERVICE PARTS, please contact the dealer from which you purchased the unit, or call Magnum Power Products LLC to locate a dealer in your area.

Engine Make:__________________________________________

Engine Serial Number:___________________________________

Engine Model Number: __________________________________

Generator Make: _______________________________________

Generator Model Number:________________________________

Generator Serial Number: ________________________________

Unit Model Number:_____________________________________

Unit Serial Number: _____________________________________

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.

2

TABLE OF CONTENTS

Page INTRODUCTION ................................................................................................................................ 2 SAFETY NOTES ................................................................................................................................ 5 OPERATING SAFETY ....................................................................................................................... 5 ENGINE SAFETY............................................................................................................................... 6 ELECTRICAL SAFETY ...................................................................................................................... 6 TOWING SAFETY.............................................................................................................................. 7 REPORTING TRAILER SAFETY DEFECTS ..................................................................................... 7 SAFETY SYMBOL SUMMARY .......................................................................................................... 8 SPECIFICATIONS - MMG75CAN6 .................................................................................................... 9 SPECIFICATIONS - MMG100CAN6 ................................................................................................ 10 UNIT DIMENSIONS ......................................................................................................................... 11 UNIT SERIAL NUMBER LOCATIONS ............................................................................................. 12 COMPONENT LOCATIONS ............................................................................................................ 13 MAIN CONTROL PANEL FEATURES ............................................................................................. 14 MAGNUM DIGITAL CONTROLLER (MDC) ..................................................................................... 16 DIGITAL CONTROLLER FEATURES AND FUNCTIONS ............................................................... 16 GENERATOR MONITORING .......................................................................................................... 17 ENGINE MONITORING ................................................................................................................... 18 WET STACKING .............................................................................................................................. 19 FINE VOLTAGE ADJUSTMENT ..................................................................................................... 19 PRE-START CHECKLIST ................................................................................................................ 20 ENGINE BREAK-IN REQUIREMENTS............................................................................................ 20 MANUAL STARTING OF THE GENERATOR ................................................................................. 21 AUTO (REMOTE) STARTING OF THE GENERATOR ................................................................. 22 SHUTTING DOWN........................................................................................................................... 23 MDC CONTROLLER INFORMATION DISPLAYS, FUNCTIONS, AND RESET ............................. 23 MAGNUM DIGITAL CONTROLLER (MDC) - GENERATOR OPERATIONAL STATUS ................. 23 MAGNUM DIGITAL CONTROLLER (MDC) - ALARM MANAGEMENT........................................... 24 MAGNUM DIGITAL CONTROLLER (MDC) - LIST OF ALARMS .................................................... 24 JOHN DEERE ECU INFORMATION DISPLAYS AND FUNCTIONS .............................................. 25 MAGNUM DIGITAL CONTROLLER (MDC) - HISTORY.................................................................. 26 ADJUSTING THE DISPLAY BACKLIGHTING ................................................................................. 27 RESETTING THE TIME TO SERVICE REMINDER...................................................................... 27 TROUBLESHOOTING AUTOMATIC SHUTDOWN CONDITIONS ................................................. 27 GENERATOR OUTPUT CONNECTION LUGS ............................................................................... 29 VOLTAGE SELECTOR SWITCHES ................................................................................................ 29 4-POSITION VOLTAGE SELECTOR SWITCH OPTION................................................................. 31 EMERGENCY STOP SWITCH ........................................................................................................ 33 MAIN CIRCUIT BREAKER............................................................................................................... 33 GENERATOR BOX CIRCUIT BREAKERS ...................................................................................... 33 VOLTAGE REGULATION ................................................................................................................ 34 CUSTOMER CONVENIENCE RECEPTACLES .............................................................................. 34 DERATING FOR ALTITUDE ............................................................................................................ 34 REMOTE START TERMINAL BLOCK ............................................................................................. 34 TRANSFER SWITCH ....................................................................................................................... 34 AUTO EXERCISE TIMER ................................................................................................................ 35 DAILY WALK AROUND INSPECTION ............................................................................................ 36 ENGINE AND GENERATOR MAINTENANCE ................................................................................ 36 BASIC MAINTENANCE SCHEDULE - JOHN DEERE ENGINE...................................................... 37 BELT TENSIONERS ........................................................................................................................ 38 LIFTING THE GENERATOR............................................................................................................ 38 TOWING THE TRAILER .................................................................................................................. 38 TRAILER WHEEL BEARINGS ......................................................................................................... 38 JACK MAINTENANCE ..................................................................................................................... 39 CHECKING GENERATOR DRIVE PLATE TORQUE ...................................................................... 39 VISCOUS FAN CLUTCH.................................................................................................................. 39

3

AUXILIARY FUEL TANK OPTION ................................................................................................... 40 FUEL TRANSFER PUMP OPTION.................................................................................................. 40 AC WIRING DIAGRAM - MMG75CAN6........................................................................................... 41 AC WIRING DIAGRAM - MMG100CAN6......................................................................................... 42 AC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT................................................................ 43 DC WIRING DIAGRAM .................................................................................................................... 44 DC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT................................................................ 45 WIRING BLOCK DIAGRAM - DEDICATED 12 LEAD GENERATORS OPTION............................. 46 TRAILER LIGHTS WIRING DIAGRAM ............................................................................................ 47 WIRING HARNESS - ELECTRIC BRAKE OPTION......................................................................... 48 SERVICE LOG ................................................................................................................................. 49 NOTES ............................................................................................................................................. 50

4

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. The following formatting options will apply when calling the readers attention to the DANGERS, WARN- INGS, CAUTIONS, NOTICES and NOTES.

DANGER INDICATES A HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN

DEATH OR SERIOUS INJURY.

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious

injury.

CAUTION Indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.

Indicates a hazardous situation which, if not avoided, may result in property or equipment damage.

Note: Notes contain additional information important to a procedure and will be found within the regular text body of this manual.

OPERATING SAFETY

Before using the generator be sure to read and understand all of the instructions. This equipment was designed for specific applications; DO NOT modify or use this equipment for 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 and proper use of all instruments and controls. Inexperienced operators should receive instruction from someone familiar with the equipment before being allowed to operate or set up the generator. The following points should be practiced at all times:

The area immediately surrounding the generator should be dry, clean, and free of debris.

NEVER start a unit in need of repair.

Make certain the generator is securely fastened to a good earthen ground before use.

NEVER operate unit on a combustible surface.

NEVER operate the generator if any of the following conditions exist during operation: 1. Noticeable change in engine speed. 2. Loss of electrical output. 3. Equipment connected to the generator 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 120F (49C).

Make sure slings, chains, hooks, ramps, jacks, and other types of lifting devices are attached securely and have enough weight-bearing capacity to lift or hold the equipment safely. Always remain aware of the position of other people around you when lifting the equipment.

NEVER operate a unit while tired, distracted, or under the influence of drugs or alcohol.

5

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.

DO NOT run engine indoors or in an area with poor ventilation. Diesel engine exhaust contains carbon monoxide, a deadly, odorless and colorless gas which, if inhaled, can cause nausea, fainting or death. Only use this unit outside and away from windows, doors, and ventillation equipment.

DO NOT fill fuel tank near an open flame, while smoking, or while engine is running. DO NOT fill tank in an enclosed area with poor ventilation.

DO NOT operate with the fuel tank cap loose or missing.

DO NOT touch or lean against hot exhaust pipes or engine cylinders.

DO NOT clean air filter with gasoline or other types of low flash point solvents.

DO NOT remove engine coolant cap while engine is hot.

DO NOT operate the unit without a functional exhaust system.Prolonged exposure to sound levels in excess of 85 dB(A) can cause permanent hearing loss. Wear hearing protection when working around a running engine.

Keep hands, feet and loose clothing away from moving parts on the generator and engine.

Keep area around exhaust pipes and air ducts free of debris to reduce the chance of an accidental fire.

Batteries contain sulfuric acid which can cause severe injury or death. Sulfuric acid can 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 corresponding terminal before performing any service on the engine or other components.

ELECTRICAL SAFETY

The unit is powered by a generator driven by a diesel engine. While the engine is running, potentially lethal voltages are present at the 120V Ground Fault Circuit Interrupt (GFCI) receptacles and the 240V twist-lock receptacles located on the control panel, and at the connection lugs and optional cam lock receptacles. Failure to follow the safety guidelines described below could result in severe injury or death.

Only a qualified and licensed electrician should make connections to the generator.

NEVER wash the unit with any high pressure hoses or power washers.

NEVER 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. A transfer switch must be used in the Auto mode to deflect the load upon startup.

ALWAYS disconnect the NEGATIVE (-) battery cable from the corresponding terminal before performing any service on the engine, generator or any other components. Remove the negative (-) battery cable from the corresponding terminal if the unit is to be stored or transported.

ALWAYS use extreme caution when servicing this unit in damp conditions. Do not service the unit if your skin or clothing is wet. Do not allow water to collect around the base of the unit.

ALWAYS connect the unit to a good earthen ground before use. Follow any local, state or United States National Electric Code (NEC) guidelines.

6

TOWING SAFETY

Towing a trailer requires care! Both the trailer and vehicle must be in good condition and securely fastened to each other to reduce the possibility of an accident. Also, some states require that large trailers be registered and licensed. Contact your local Department of Transportation office to check on license requirements for your particular unit.

Check that the hitch and coupling on the towing vehicle are rated equal to, or greater than, the trailer's Gross Vehicle Weight Rating (GVWR).

Check tires on trailer for tread wear, inflation, and condition.

NEVER tow trailer using defective parts! Inspect the hitch and coupling for wear or damage.

Make sure the trailer hitch and the coupling are compatible. Make sure the coupling is securely fastened to the vehicle.

Connect safety chains in a crossing pattern under the tongue and ATTACH THE BREAKAWAY CABLE TO THE REAR BUMPER OF THE TOWING VEHICLE. Do not attach the cable to the trailer hitch.

Make sure directional and brake lights on the trailer are connected and working properly.

Check that lug nuts holding wheels are tight and that none are missing.

Maximum recommended 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 the trailer is equal across all tires. On trailers with adjustable height hitches, adjust the angle of the trailer tongue to keep the trailer as level as possible. On units equipped with a tandem axle trailer, a large angle between the trailer and tow vehicle will cause more weight to be carried by one axle, which could cause premature wear on the tires and axles and cause potentially unsafe operating conditions.

The trailer is equipped with hydraulic surge brakes or electric surge brakes. Check the operation of the brakes by braking the vehicle at a slow speed before entering traffic. Both the trailer and the vehicle should brake smoothly. If the trailer seems to be pushing, check the level in the surge brake fluid reservoir.

When towing, maintain extra space between vehicles and avoid soft shoulders, curbs and sudden lane changes. If you have not pulled a trailer before, practice turning, stopping, and backing up in an area away from heavy traffic.

A film of grease on the coupler will extend coupler life and eliminate squeaking. Wipe the coupler clean and apply fresh grease each time the trailer is towed.

REPORTING TRAILER SAFETY DEFECTS

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 Power 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. However, NHTSA cannot become involved in individual problems between you, your dealer, or Magnum Power Products LLC.

To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-888-327-4236 (TTY:1-800-424-9153), go to http://www.safercar.gov; or write to:

Administrator NHTSA 1200 New Jersey Avenue S.E. Washington, DC 20590

You can also obtain other information about motor vehicle safety from http://www.safercar.gov.

7

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 manual. Below is a summary of the intended meanings for the symbols used on the decals.

Hot surface(s) nearby.

Fire/explosion hazard; keep open flames away from unit.

Read and understand the supplied operators manual before operating unit.

Remove negative battery cable before performing any service on unit.

Stop engine before making connections.

Use clean diesel fuel only.

Unit electrical ground. Hearing protection required while operating unit with doors open.

Anchor/tie down point.

Lift here only.

Asphyxiation hazard; operate in well ventilated area.

Dangerous voltage may be present.

Never change switch position while engine is running.

Burn/scald hazard; pressurized steam.

Fan hazard; keep body parts clear of this area.

Isolate generator to prevent electrocution hazard.

Belt/entanglement hazard; keep body parts clear of this area.

Safety alert symbol; used to alert you to potential personal injury hazards.

Stop engine before fueling.

Engine running.

8

SPECIFICATIONS - MMG75CAN6

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 setup, use and service requirements. SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

MAGNUM MODEL MMG75CAN6

Engine Make/Brand.............................................................................................................................John Deere Model ......................................................................................................................................PE4045TF285 Horsepower - prime hp (kW) .................................................................................................91 (68) Horsepower - standby hp (kW) ..............................................................................................99 (74) Operating Speed rpm ............................................................................................................1800 Displacement in3 (L) ..............................................................................................................274 (4.5) Cylinders - qty .........................................................................................................................4 Fuel Consumption - 100% prime gph (Lph) ..........................................................................5.6 (21.2) Battery Type............................................................................................................................Group 24 Battery Voltage (Quantity per Unit) .........................................................................................12V (1) Battery Rating .........................................................................................................................720 CCA

Generator Make/Brand.............................................................................................................................Marathon Electric Model ......................................................................................................................................361PSL1670 Type, Insulation.......................................................................................................................Brushless, H

Generator Set (Engine/Generator) 600V (3) 480V (3) 208V (3) 240V (1)

3 - Standby kW (kVA) ........................63 (79) ............... 62 (78)............... 53 (66) ...............0 (0) Amps - 3 Standby A ...........................76 ...................... 93 ...................... 184.....................0 3 - Prime kW (kVA) ...........................58 (72) ............... 58 (72)............... 52 (65) ...............0 (0) Amps - 3 Prime A ...............................69 ...................... 87 ...................... 180.....................0 1 - Standby kW (kVA).........................0 (0) ................... 0 (0)................... 0 (0) ...................31 (31) Amps - 1 Standby - 240V A................0 ........................ 0 ........................ 0.........................129 1 - Prime kW (kVA) ............................0 (0) ................... 0 (0)................... 0 (0) ...................29 (29) Amps - 1 Prime - 240V A ...................0 ........................ 0 ........................ 0.........................121 Frequency Hz .........................................................................................................................60 Power Factor...........................................................................................................................1 (1), 0.8 (3) Sound dB(A) 23 ft. @ prime .................................................................................................68

Weights Dry Weight, Skid Mounted lbs (kg) ........................................................................................3178 (1442) Operating Weight, Skid Mounted lbs (kg) .............................................................................4222 (1915) Dry Weight, Trailer Mounted* lbs (kg) ...................................................................................3913 (1775) Operating Weight, Trailer Mounted* lbs (kg) .........................................................................4957 (2248) *Standard single axle trailer only. Consult factory for dual axle or custom trailer weights.

Capacities Fuel Tank Volume gal (L) .......................................................................................................147 (556) Usable Fuel Volume gal (L) ...................................................................................................135 (511) Coolant (incl. engine) qt (L) ...................................................................................................26.0 (24.6) Oil (incl. filter) qt (L) ...............................................................................................................15.5 (14.7) Maximum Run Time hrs ........................................................................................................24

AC Distribution Circuit Breaker Size ................................................................................................................300 Voltage Selection ....................................................................................................................3 Position Switch (lockable) Voltage Regulation..................................................................................................................+/- 1% Voltages Available 1.............................................................................................................120, 139, 208, 220, 240, 277 Voltages Available 3.............................................................................................................208, 220, 440, 480, 600

Trailer Number of Axles .....................................................................................................................1 Capacity - Axle Rating lbs (kg) ..............................................................................................6000 (2722) Tire Size in .............................................................................................................................15 Brakes.....................................................................................................................................Surge Hitch - Standard ......................................................................................................................3" Ring Maximum Tire Pressure psi ...................................................................................................65

9

SPECIFICATIONS - MMG100CAN6

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 setup, use and service requirements. SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

MAGNUM MODEL MMG100CAN6

Engine Make/Brand.............................................................................................................................John Deere Model ......................................................................................................................................PE4045TF285 Horsepower - prime hp (kW) .................................................................................................122 (91) Horsepower - standby hp (kW) ..............................................................................................133 (99) Operating Speed rpm ............................................................................................................1800 Displacement in3 (L) ..............................................................................................................274 (4.5) Cylinders - qty .........................................................................................................................4 Fuel Consumption - 100% prime gph (Lph) ..........................................................................6.2 (23.5) Battery Type............................................................................................................................Group 24 Battery Voltage (Quantity per Unit) .........................................................................................12V (1) Battery Rating .........................................................................................................................720 CCA

Generator Make/Brand.............................................................................................................................Marathon Electric Model ......................................................................................................................................362PSL1667 Type, Insulation.......................................................................................................................Brushless, H

Generator Set (Engine/Generator) 600V (3) 480V (3) 208V (3) 240V (1)

3 - Standby kW (kVA) ........................85 (106) ............. 77 (96)............... 66 (83) ...............0 (0) Amps - 3 Standby A ...........................102 .................... 116 .................... 229.....................0 3 - Prime kW (kVA) ...........................78 (97) ............... 72 (90)............... 62 (78) ...............0 (0) Amps - 3 Prime A ...............................93 ...................... 108 .................... 215.....................0 1 - Standby kW (kVA).........................0 (0) ................... 0 (0)................... 0 (0) ...................37 (37) Amps - 1 Standby - 240V A................0 ........................ 0 ........................ 0.........................154 1 - Prime kW (kVA) ............................0 (0) ................... 0 (0)................... 0 (0) ...................35 (35) Amps - 1 Prime - 240V A ...................0 ........................ 0 ........................ 0.........................146 Frequency Hz .........................................................................................................................60 Power Factor...........................................................................................................................1 (1), 0.8 (3) Sound dB(A) 23 ft. @ prime .................................................................................................68

Weights Dry Weight, Skid Mounted lbs (kg) ........................................................................................3402 (1543) Operating Weight, Skid Mounted lbs (kg) .............................................................................4361 (1978) Dry Weight, Trailer Mounted* lbs (kg) ...................................................................................4104 (1860) Operating Weight, Trailer Mounted* lbs (kg) .........................................................................5062 (2296) *Standard single axle trailer only. Consult factory for dual axle or custom trailer weights.

Capacities Fuel Tank Volume gal (L) .......................................................................................................147 (556) Usable Fuel Volume gal (L) ...................................................................................................135 (511) Coolant (incl. engine) qt (L) ...................................................................................................22.0 (20.8) Oil (incl. filter) qt (L) ...............................................................................................................15.5 (14.7) Maximum Run Time hrs ........................................................................................................22

AC Distribution Circuit Breaker Size ................................................................................................................400 Voltage Selection ....................................................................................................................3 Position Switch (lockable) Voltage Regulation..................................................................................................................+/- 1% Voltages Available 1.............................................................................................................120, 139, 208, 220, 240, 277 Voltages Available 3.............................................................................................................208, 220, 440, 480, 600

Trailer Number of Axles .....................................................................................................................1 Capacity - Axle Rating lbs (kg) ..............................................................................................6000 (2722) Tire Size in .............................................................................................................................15 Brakes.....................................................................................................................................Surge Hitch - Standard ......................................................................................................................3" Ring Maximum Tire Pressure psi ...................................................................................................65

10

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 setup, use and service requirements. SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

MAGNUM MODELS MMG75CAN6/MMG100CAN6

Dimensions (L x W x H) Skid Mounted in (m) ..................................................................................................... 96 x 38 x 62 (2.44 x 0.97 x 1.58) Trailer Mounted in (m) .................................................................................................. 158 x 60 x 84 (4.01 x 1.52 x 2.13)

W L

H

W L

H

11

UNIT SERIAL NUMBER LOCATIONS

Refer to the locations illustrated below to find the unit ID tag and VIN tag on your unit. Important information, such as the unit serial number, model number and Vehicle Identification Number (VIN) for your trailer are found on these tags. Record the information from these tags, so it is available if the tags are lost or damaged. When ordering parts or requesting technical service information, you may be asked to provide this information.

Serial Number

V

A

Model

KVA

FOR ELECTRICAL EQUIPMENT ONLY. POUR MATERIAL

ELECTRIQUE SEULEMENT.

Mfg. Code

Skidded WT (lbs/kg) rpm/freq

1 ph. 1.0PF 3 ph. .8PF 3 ph. 1.0PF

insul. class RATING

KW

MAGNUM POWER PRODUCTS LLC Manufactured by

A wholly owned subsidiary of Generac Power Systems, Inc.

215 Power Drive Berlin, WI 54923 1-800-926-9768

UNIT ID Tag

Located on control panel.

VIN Tag TIRE AND LOADING INFORMATION

RENSEIGNEMENTS SUR LES PNEUS ET LE CHARGEMENT

SEE OWNERS MANUAL FOR ADDITIONAL

INFORMATION VOIR LE

MANUEL DE LUSAGER

POUR PLUS DE

RENSEIGNEMENTS

MANUFACTURED BY/FABRIQUE PAR: Magnum Power Products LLC DATE: 00/0000 GVWR/PNBV: 000KG (0000LBS) COLD INF. PRESS./ PRESS. DE

V.I.N./N.I.V.:

00000000000000000

TYPE:

TRAILER

MODEL:

XXX000

GAWR / PNBE TIRE / PNEU RIM / JANTE GONF A FROID - KPA(PSI/LPC) SGL / DUAL

EACH AXLE

THIS VEHICLE CONFORMS TO ALL APPLICABLE STANDARDS PRESCRIBED UNDER THE U.S. FEDERAL MOTOR VEHICLE SAFETY STANDARDS(FMVSS) AND CANADIAN MOTOR VEHICLE SAFETY REGULATIONS IN EFFECT ON THE DATE OF MANUFACTURE.

CE VEHICULE EST CONFORME A TOUTES LES NORMES QUI LUI SONT APPLICABLES EN VERTU DU REGLEMENT SUR LA SECURITE DES VEHICULES AUTOMOBILES DU CANADA EN VIGUEUR A LA DATE SA FABRICATION.

The weight of cargo should never exceed 0000KG (0000LBS) Le poids du chargement ne doit jamais depasser 0000KG (0000LBS)

12

COMPONENT LOCATIONS

Radiator Access Panel

Engine Access

Engine Access

Engine Exhaust

Emergency Stop

Oil Drain Port

Radiator Drain Port

Control Panel

Access

Central Lift Point

Fuel Fill

LEFT SIDE

RIGHT SIDE

Voltage Selector Switch Access

Engine Battery Access

13

MAIN CONTROL PANEL FEATURES

Ready PF 0.00 RPM 0

MAN AUT

k 4

3

2

1

12

11

10

9

8

65 7

CAUTION Do not use 120V GFCI outlets when generator at 480 or 600 volts. Equipment damage or personal injury may result.

CAUTION Do not use 240V twist lock outlets when generator at 600 volts. Equipment damage or personal injury may result.

14

1. GENERATOR GROUND CONNECTION LUG: This lug is for connecting a good earthen ground per any local, state or National Electric Code (NEC) guidelines before starting the generator.

2. GENERATOR OUTPUT CONNECTION LUGS: These lugs allow appropriate loads to be wired directly to the generator.

3. CONNECTION FOR BATTERY CHARGER (Optional): This receptacle allows for 120VAC input to power an onboard battery charger.

4. MAIN CIRCUIT BREAKER: This breaker will disconnect power to the connection lugs (items 1-2). It WILL NOT disconnect power to the convenience receptacles when the engine is running.

5. AUXILIARY LIGHT SWITCHES: These switches operate optional control panel and interior lights.

6. AIR FILTER METER: This gauge shows the condition of the air filter when the engine is running.

7. MAGNUM DIGITAL CONTROLLER (MDC): Refer to Magnum Digital Controller (MDC) on page 16.

8. 20A CIRCUIT BREAKERS: Circuit breakers for the 120V GFCI receptacles.

9. 120V GFCI DUPLEX CONVENIENCE RECEPTACLES: Used for connecting additional loads or equipment to the generator.

10. 50A CIRCUIT BREAKERS: Circuit breakers for the 120/240V twist-lock receptacles.

11. 120/240V TWIST-LOCK CONVENIENCE RECEPTACLES: Used for connecting additional loads or equipment to the generator.

12. REMOTE START TERMINAL BLOCK: This terminal block allows the generator to be started from a remote location with a dry-contact closure switch when the generator is used for standby or remote power.

15

MAGNUM DIGITAL CONTROLLER (MDC)

The 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 shutdown; to resume operation, the fault condition must be resolved. The controller has the ability to provide the display readout in English and Spanish; other languages are available. A screen print out of the display screen is also available. This controller also records a history of the units performance which may be viewed at any time and will not be removed or lost when the controller is powered down.

The MDC panel consists of five sections: the CONTROL ON/OFF toggle switch and fine voltage adjustment screw, the OPERATION keypad, the LCD window, the DIAGNOSTICS keypad, and the STATUS Light Emitting Diodes (LEDs).

DIGITAL CONTROLLER FEATURES AND FUNCTIONS

1. The CONTROL ON/OFF Toggle Switch and Fine Voltage Adjustment Screw CONTROL ON/OFF toggle switch: This toggle switch powers-up and switches offthe control panel and

the controller. Fine Voltage Adjustment Screw: This screw may be adjusted to set the generator output voltage after the

link board or voltage selector switch has been changed from one phase to another. This adjustment MUST be accomplished within 45 seconds of start-up, during the V Detect, so that the unit does not experience a shutdown alarm for over or under voltage. Refer to Fine Voltage Adjustment on page 19 for more information.

2. The OPERATION Keypad ENGINE START button: The Power Display screen must be in the MAN mode in the upper left corner

of the LCD window display and the READY/MANUAL LED lit in the STATUS portion of the controller. Press the green ENGINE START button to start the unit.

ENGINE STOP button: Press the red ENGINE STOP button to shut down the unit and start the Stop Value timer.

16

MANUAL button: Press this button to change from the automatic (remote) starting mode to manual starting mode.

AUTO button: Press this button to change from manual starting mode to automatic (remote) starting mode.

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. Press FAULT RESET and ENTER to clear the John Deere ECU Alarm List codes.

3. The Liquid Crystal Display (LCD) This window will toggle between the Generator Display screen and the Engine Display screen upon start-up

of the unit. By viewing these screens, the operator will be able to monitor both the engine and generator status while the unit is running.

4. The DIAGNOSTICS Keypad Scroll Up button: Press this button to scroll up within the LCD window. Scroll Down button: Press this button to scroll down within the LCD window. PAGE SELECT button: Pressing this button will select the next display screen. ENTER button: Pressing this button will place you inside the particular display to review the generators

pre-programmed setpoints or parameters.

5. The STATUS Light Emitting Diodes (LEDs) These six LEDs will illuminate to display the current operational status of the generator:

ALARM/FAULT: Indicates active or inactive alarms, but not reset shutdown alarms. WARNING: Indicates an active or inactive alarm, or a warning alarm 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 ready for the remote start signal. RUNNING: Indicates the unit is running. SUPPLYING LOAD: Indicates a load is being applied to the generator.

GENERATOR MONITORING

Generator information is shown on the Liquid Crystal Display (LCD) window in a toggling manner with the engine information after the first 60 seconds of operation, then every five seconds thereafter. The Generator Display screen will show frequency, nominal voltage, nominal amperage, line to neutral voltage, line to line voltage and amperage.

Note: When loading the generator, it is important to observe the amperage to determine the load balance on each line of the generator. Minor load unbalances, usually 10% or less, will not cause any particular problems. Every effort should be made to distribute the load equally between all lines.

Hertz: Displays output frequency. Generator Output Voltage: Line to neutral display, single phase (1). Generator Output Voltage: Line to line display, 3 phase (3). Amps: Displays the AC output amperage produced by the generator.

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ENGINE MONITORING

Engine information is shown on the Liquid Crystal Display (LCD) window in a toggling manner with the generator information after the first 60 seconds of operation and then every five seconds thereafter. The Engine Display screen will show oil pressure, engine coolant temperature, fuel level and battery voltage.

Oil Pressure: Displays engine oil pressure. The display registers oil pressure between 0-100 psi (10-689 kPa). Normal operating pressure is between 35-80 psi (241-552 kPa).

Engine Temp: Displays the temperature of the engines coolant. If the coolant temperature exceeds the maximum water temperature of 230F (110C) the engine will automatically shut down. Zero will be displayed until a minimum temperature of 100F (38C) is reached.

Fuel Level: Displays the level of fuel in the tank by percentage (50% = 1/2 tank, 75% = 3/4 tank, etc.). If the fuel level drops below a programmed low fuel point, usually at 15%, a low fuel warning and optional audio alarm will be activated. If the fuel level drops below the programmed low fuel limit, usually at five percent, the engine will automatically shut down.

Battery Volts: Displays the engine battery voltage. A normal reading is 13-14V on 12 volt systems and 24- 26V on 24 volt systems (with the engine running).

Additional information may be viewed while the unit 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 operator may press the or buttons on the DIAGNOSTICS keypad to display additional information as follows:

Running screen: The operator may press the or buttons on the DIAGNOSTICS keypad to display the Alarm List screen, ECU Alarm List screen, Run Hours screen, ECU Values screen, Engine Display screen and Generator Display screen.

18

Password screen: The operator may press the or buttons on the DIAGNOSTICS keypad to move the cursor (>) up or down a list of text.

History screen: The operator may press the or buttons on the DIAGNOSTICS keypad to move the cursor (>) up or down a list of recent alarm or shutdown codes. Pressing the ENTER button at a particular selection will allow the operator to scroll to the right in the LCD window to view the generator operating parameters at the time of the alarm or shutdown. The history of alarms or codes is saved in the digital controller. The most recent alarm or code is the first to be listed, with the time/date of the alarm or code at the bottom of the screen. The controller stores up to 117 codes. When full, the controller will automatically remove the oldest file. These codes will not be lost when the CONTROL ON/OFF toggle switch is powered off.

Note: To view the display screens longer, push the PAGE SELECT button on the DIAGNOSTICS keypad until you reach the Ready screen. Then press the or buttons to navigate to the screens you want. The screens will display for approximately 45 seconds.

WET STACKING

The generator is powered by a diesel engine. Diesel engines are susceptible to wet stacking if lightly loaded. Wet stacking occurs when an engine is run at less than 30% of its full load capacity, causing unburned fuel to accumulate in the exhaust system. Wet stacking can be detected by continuous black exhaust when the unit is under a constant load. It can also cause fouling of injectors and buildup on engine valves. Diesel engines operate properly when applied loads are between 30% and 100% capacity. Appropriate generator sizing is determined by the anticipated load. If the unit is in a wet stack condition, load the unit heavily for five hours or until the exhaust is clear.

FINE VOLTAGE ADJUSTMENT

Upon startup of the generator, the Running screen of the Magnum Digital Controller (MDC) will display V Detect and will countdown from 45 seconds to zero. This is a safety feature of the controller to protect the generator from over or under voltage upon startup.

V Detect is a 45 second time delay and countdown process before the MDC records the generator nominal output voltage. This nominal generator voltage is then compared to the current set point voltage of the voltage selector switch. If the nominal voltage recorded by the controller is greater than or lower than the current set point voltage of the voltage selector switch setting by 10% or more, the controller will shut the generator down automatically. The display will read: Wrn Gen L1

The output voltage of the generator may be adjusted after the generator is running by using the fine voltage adjustment screw. The adjusting screw is located directly below the CONTROL ON/OFF toggle switch on the control panel.

CONTROL ON

CONTROL OFF

Voltage Adjustment

Screw

19

This screw turns a rheostat that will provide an increase (+) or a decrease (-) in the generator output voltage as displayed on the generator display screen on the MDC. If the voltage is increased or decreased too fast or too slow, the unit will automatically shut down. This adjustment needs to be made within the 45 second delay and countdown to zero period.

To adjust the output voltage, check the output voltage on the Liquid Crystal Display (LCD) window labeled Gen freq & Hz. Look at the L1N voltage or the L12 voltage on the display. The generator nominal output voltage should be within 10% of the voltage rating on the voltage selector switch.

To adjust the output voltage, use a flat head screwdriver to turn the screw in the desired direction until the required voltage shown on the LCD window matches the stated voltage on the voltage selector switch.

For Example: With the voltage selector switch set to 208/120V 3 phase position, the voltage displayed on the Gen freq & Hz screen must be within 10% of the 208/120 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 adjustment will need to be made using the fine voltage adjustment screw.

PRE-START CHECKLIST

Before starting the generator, carefully read the pre-start check list. Make sure 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. 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 to a good earthen ground per any local and National

Electric Code (NEC) regulations. Verify all electrical connections at the connection lugs are tight and wired correctly. Check the voltage selector switch and make sure that it is set to the desired voltage. Is the voltage selector switch locked? Is the generator sitting level? Thoroughly check for any water inside the unit, on, or near the generator. Dry the unit before starting. Check oil, coolant, and fuel levels, and engine battery connections. Check the engine fan belt tension and condition. Check the engine fan belt guard. Check the engine exhaust system for loose or rusted components. Check the radiator and surrounding shroud for debris. Are any of the generator covers loose or missing? Are all preventive maintenance procedures up to date? Check that the battery disconnect switch is on, if equipped.

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.

John Deere engines are supplied with engine break-in oil from the factory. Extra care during the first 100 hours of engine operation will result in better performance and longer engine life. DO NOT exceed 100 hours of operation with the break-in oil. Operate the engine at heavy loads (60-90% of maximum) as much as possible. If the engine has spent significant time at idle, constant speed(s), and/or light load, or if makeup oil is required, a longer break-in period may be needed. Consult the engine operators manual for a full description of necessary procedures on the addition of break-in oil and extension of the break-in period. For more information on regular maintenance intervals, refer to Basic Maintenance Schedule - John Deere Engine on page 37.

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MANUAL STARTING OF THE GENERATOR

1. Move the CONTROL ON/OFF toggle switch to the CONTROL ON/I position.

DANGER CARBON MONOXIDE: USING A GENERATOR INDOORS CAN KILL YOU IN MINUTES!

2. The Liquid Crystal Display (LCD) window will quickly display system information, all Light Emitting Diodes (LEDs) will flash.

3. The LCD window will indicate MAN (Manual) mode and Ready. The READY/MANUAL LED will be lit.

Note: The unit must be in the MAN mode with the READY/MANUAL LED lit to start the unit.

4. Press the green ENGINE START button. The Prestart 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.

21

6. The Running screen will display.

Note: It may take a few seconds for the engine to run smoothly and reach its governed operating speed. The 45 second V detect time delay will start to countdown.

7. The LCD window will then toggle from the Running screen to the generator display screen and then to the engine display screen.

8. If the engine does not start after the first cranking attempt, the engine will pause for 15 seconds to allow the starter to cool. The LCD window will show PAUSE. The engine will make two more attempts to start for a total of three crank cycles.

9. Should the engine not start and run within three starting cycles, the LCD window will show SD Start fail. The starting sequence may be repeated after the starter has had a minimum of two minutes to cool. Press the FAULT RESET button to clear the controller. To start the unit, press the green ENGINE START button.

Note: The engine controller may skip the preheat engine steps on some of the larger models.

10. Once the 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 warmed up and the LCD window will show engine and generator operating parameters. Temperature will be shown as 0 until the engine temperature is approximately 100F (38C).

11. Check the generator for excessive noise or vibration and any coolant, oil or fuel leaks before applying any loads.

12. Check that the AC output voltage is correct. The output voltage can be fine adjusted by using the fine voltage adjustment screw (rheostat). Refer to Fine Voltage Adjustment on page 19.

13. Check that the frequency (Hz) is correct. With no loads connected to the generator, the frequency should read approximately 60 Hz, depending on the type of engine governing used.

14. If all wiring connections have been attached and secured correctly, switch the main circuit breaker to the ON/I position and then add any loads attached to the convenience receptacles by switching the respective circuit breaker to the ON/I position. You will notice a slight change in engine sound when a load is applied to the unit.

AUTO (REMOTE) STARTING OF THE GENERATOR

The AUTO button is used when the generator is started from a location other than the control panel and by using a transfer switch. AUTO (remote start) is the normal setting when the generator is being used as a standby power supply. Before putting the generator in the AUTO mode, review the Pre-Start Check List and Manual Starting of the Generator. Refer to Pre-Start Checklist on page 20 and Manual Starting Of The Generator on page 21. Follow all safety warnings and information on isolating the generator with a transfer switch if the unit is to be used as a standby

22

power supply. Refer to Transfer Switch on page 34. Then continue with the steps described below:

1. Perform a manual start of the generator at least once to verify the engine is operating correctly. 2. If a check of the remote start circuit is desired, remove the wires from the remote start terminal block.

Press the AUTO button, the Liquid Crystal Display (LCD) window should highlight AUT in the upper left corner. 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.

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 switch) to the remote start terminal block.

4. Confirm unit is in AUTO mode. The LCD window should have AUT highlighted in the upper left corner. 5. Close the main circuit breaker (set to ON/I). 6. Secure the generator by closing and locking all access doors. 7. The generator is now ready for remote starting. Refer to Remote Start Terminal Block on page 34.

SHUTTING DOWN

Check with personnel using power supplied by the generator and let them know the power is going to be turned off. Make sure the power shut down will not create any hazards by accidentally turning off equipment that needs to be kept on (pumps, compressors, lights, etc.).

1. Remove all loads from the generator by opening all circuit breakers (turn to OFFO). 2. Let the engine run for approximately five minutes to allow it to cool down. 3. Push the red ENGINE STOP button. Pressing ENGINE STOP will result in the generator going into

the shut down cycle and starting a 15 second shut down timer called Stop Value. If the unit does not shut down within 15 seconds, a Stop Fail alarm will be displayed on the Liquid Crystal Display (LCD) window.

4. Move the CONTROL ON/OFF toggle switch to the CONTROL OFF/O position.

Note: For extended storage time, disconnect the battery. Refer to the operators manual for extended storage requirements.

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 shutdown. To resume operation, the fault condition must be resolved. To reset the controller and resume operation, press the FAULT RESET button.

The operation of the Magnum Digital Controller is divided into the following sections:

MAGNUM DIGITAL CONTROLLER (MDC) - GENERATOR OPERATIONAL STATUS

The MDC displays the operational status of the generator using the following codes:

No. Engine State Description

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 during controller power on.

6 Loaded The unit is running at nominal speed and GCB OPEN/ CLOSE is closed.

7 Not Ready The unit is not ready to start.

8 Pause Pause between start attempts.

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MAGNUM DIGITAL CONTROLLER (MDC) - ALARM MANAGEMENT

The MDC is capable of displaying the following alarms:

MAGNUM DIGITAL CONTROLLER (MDC) - LIST OF ALARMS

Shutdown and warning fault conditions and the displayed message are described in the following table:

9 Prestart Prestart sequence in process, prestart output is closed.

10 Ready The unit is ready to run.

11 Running The unit is running at nominal speed.

12 Shutdown Shutdown alarm is activated.

13 Starting Starting speed is reached and the idle timer is running.

14 Stop Stop.

No. Electrical State Description

1 StabilTO Stabilization Timeout

No. Type Description

1 Sensor fail (FLS)

Sensor fail is detected when measured value is 6% out of the selected characteristic. Sensor fail is indicated by ##### symbol instead of measured value. Note: Oil Temp for John Deere engines will always display as #####.

2 Warning (WRN) When warning comes up, see list of possible alarms.

3 Shutdown (SD) When the shutdown alarm comes up, the digital controller opens outputs GCB CLOSE/OPEN, FUEL, SOLENOID, STARTER and PRESTART to stop the engine immediately.

No. Events

Specification Protection

Type

Information on Binary Output

Available Description

1 AnInIOM Sd SD YES Shutdown alarm configurable on the input of IG-IOM/ IGS-PTM.

2 AnInIOM Wrn WRN YES Warning alarm configurable on the input of IG-IOM/ IGS-PTM.

3 Battery Flat (low battery)

SD YES If the controller switches off during starting sequence due to bad battery condition, it doesnt try to start again and activates this protection.

4 Binary Input CONFIG. YES Configurable Warning/Shutdown alarms on the inputs of IL-NT.

5 ChrgAlternFail WRN YES Failure of the alternator to charge the battery.

6 EmergencyStop SD NO If the red Emergency Stop switch is pushed or opened, shutdown is immediately activated.

7 Engine Temp Sd SD NO Water temperature is greater than Sd Water Temp set- point.

8 Engine Temp Wrn WRN YES Water temperature is greater than Wrn Water Temp setpoint.

9 Fgen<, > SD YES The generator frequency is out of limits given by Gen >f and Gen setpoints.

10 Fuel Level Sd SD YES Fuel level is smaller than Sd Fuel Level setpoint (5%).

No. Engine State Description

24

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. In addition to the Alarm List, there is an ECU Alarm List which will list any faults specified by the John Deere ECU.

Press the Scroll Up button (on the diagnostic keypad) to view the ECU Alarm List. This will allow the operator to view a description of the fault, along with the diagnostic trouble codes located at the bottom of the display (see Figure 1). To further identify a fault by using these codes, refer to the John Deere Operators Manual supplied with

11 Fuel Level Wrn WRN YES Fuel level is smaller than Wrn Fuel Level setpoint (15%).

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 (low).

15 Oil Press Sd SD NO Oil pressure is smaller than Sd Oil Press setpoint.

16 Oil Press Wrn WRN YES Oil pressure is smaller than Wrn Oil Press setpoint.

17 Overload SD YES The load is greater than the value given by Overload setpoint.

18 Overspeed SD YES The protection comes active if the speed is greater than Overspeed setpoint.

19 ParamFail NONE NO

Wrong checksum of parameters. Happens typically after downloading new firmware or changing of the parameter. The controller stays in INIT mode. Check all parameters, write at least one new parameter.

20 PickupFault SD NO Failure of the magnetic pick up sensor for speed mea- surement.

21 Sd IOM fail SD NO Shutdown alarm in case of lost connection to IOM/IGS- PTM module.

22 SprinkIActive WRN NO The protection is active if the output Sprinkler is closed.

23 Start failed SD YES Unit did not start.

24 Stop fail SD YES Unit did not stop.

25 Ubat WRN YES Battery voltage is out of limits given by Batt Undervolt setpoints.

26 Underspeed SD YES

During starting of the engine, when the RPM reaches the value of Starting RPM setpoint, the starter is switched off and the speed of the engine can drop under Start RPM again. Then the Underspeed protec- tion becomes active. Protection evaluation starts 5 sec- onds after startup.

27 Vgen<, > SD YES The generator voltage is out of limits given by Gen and Gen setpoints.

28 Vgen unbal SD NO The generator voltage is unbalanced more than the value of Volt unbal setpoint.

29 Wrn ECU Alarm WRN NO ECU alarm list is not empty.

30 Wrn RA15 fail WRN NO Warning alarm in case of lost connection to IGL=RA15 module.

31 WrnMaintenance WRN NO The period for servicing is set by the WrnMaintenance setpoint. The protection comes active if the running hours of the engine reach this value.

No. Events

Specification Protection

Type

Information on Binary Output

Available Description

25

the unit. To resume operation, the fault condition must be resolved and the code cleared from the display.

Diagnostic messages are read and displayed in the ECU Alarm List. The Suspect Parameter Number (SPN)*, Failure Mode Identifier (FMI) and Occurrence 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 displayed. Detailed SPN*/FMI information may be found in the SAE HS-1939 Publication, or refer to the engine manufacturers ECU error codes list. The following table displays the ECU messages and their descriptions.

*Note: The Suspect Parameter Number (SPN) is displayed as FC on the bottom left of the LCD window. See Figure 1.

MAGNUM DIGITAL CONTROLLER (MDC) - HISTORY

The MDC stores a record of each important event in the history file of the controller. The history file seats 117 records. When the history file is full, the oldest records are removed.

No. SPN Description

1 SPN:100 EngOil Press

2 SPN:102 Boost Press

3 SPN:105 Intake Temp

4 SPN:110 EngCool Temp

5 SPN:175 EngOil Temp

6 SPN:629 Controller #1

7 SPN:636 PositionSensor

8 SPN:637 TimingSensor

9 SPN:651 InjectorCyl#1

10 SPN:652 InjectorCyl#2

11 SPN:653 InjectorCyl#3

12 SPN:654 InjectorCyl#4

13 SPN:655 InjectorCyl#5

14 SPN:656 InjectorCyl#6

15 SPN:677 EngStartRelay

16 SPN:1485 ECU MainRelay

17 SPN:3719.15 High soot load caution

18 SPN:3719.16 Very high soot load warning

19 SPN:3719.00 Very high soot load - needs service

No. Record Structure

Abbreviation Historical Value

1 AIM1 IG-IOM, IGS-PTM analog input 1 value (when configured IG-IOM, IGS-PTM)

2 Date Date of historical event in format DD/MM/YY

3 OilP IL-NT analog input 1 value (default: oil pressure)

4 FC ECU alarm FailureCode

Figure 1

26

ADJUSTING THE DISPLAY BACKLIGHTING

The brightness on the Liquid Crystal Display (LCD) window may be adjusted by the operator whenever the Magnum Digital Controller (MDC) is powered up.

Note: Anytime an * is displayed on the LCD window, the text or set point cannot be changed without the use of a password. Contact Magnum Power Products LLC Technical Support for assistance.

1. Press and hold ENTER, then press the or button on the diagnostics keypad to increase or decrease the brightness as needed.

2. Release the ENTER button when the desired brightness is attained.

RESETTING THE TIME TO SERVICE REMINDER

The Magnum Digital Controller (MDC) will display the message WrnMaintenance 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 Time to Service reminder needs to be reset to the 250 hour interval. The following procedure demonstrates how to reset the running hours to 250:

1. With the unit shut down, power up the controller with the CONTROL ON/OFF toggle switch. The initialization screen will be displayed. The controller will toggle automatically to the Ready screen.

2. Press the PAGE SELECT button. The next screen will display lines of text; starting with the word Password, then Basic Settings, Engine Params, Engine Protect etc. The top line has a > cursor before the word Password.

3. Press the button to move the > cursor down to the Engine Protect line of text. 4. Press ENTER. WrnMaintenance will appear at the top left of the display screen. The 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 under WrnMaintenance. 6. Press the button and reset the current run time hour setting to 250. If you pass the 250 time interval

use the button to get back to the 250 time interval. 7. Press ENTER to save the current run time hour setting. 8. Move the CONTROL ON/I toggle switch to the CONTROL OFF/O position.

TROUBLESHOOTING AUTOMATIC SHUTDOWN CONDITIONS

WARNING Allow engine to cool before performing any troubleshooting procedures. Contacting

the engine when it is hot will cause severe personal injury.

LOW FUEL LEVEL SHUTDOWN

1. Check the fuel level on the Liquid Crystal Display (LCD) window. Confirm the generator is sitting level to ensure an accurate reading.

5 Vg2 Generator voltage L2

6 RPM Engine speed

7 Ig2 Generator current L2

8 Ubat Battery voltage

9 FMI ECU alarm failure mode identifier

10 EngT IL-NT analog input 2 value (default: water temperature)

No. Record Structure

Abbreviation Historical Value

27

2. Check for leaks in the fuel tank. The fuel tank should not run dry under normal circ*mstances. The engine controller will shut the engine down when there is 5% of fuel remaining in the tank. This is done to keep the fuel lines from running dry.

3. If the fuel level is good and no leaks are found, check the fuel level sender and the connecting wiring for damage. To check for continuity between the sender and the engine controller, remove the appropriate bolts from the control panel to access the inside of the control box. Consult the appropriate DC wiring diagram in the parts manual for the proper path between the engine controller and the fuel level sender.

LOW OIL PRESSURE SHUTDOWN

1. Check the level of the engine oil with the dipstick. The engine controller will shut the engine down when the oil pressure is less than 20 psi (138 kPa). Add oil if required.

2. Visually inspect the engine for oil leaks. 3. If the oil level is good, restart the unit and verify the loss of oil pressure. Shut the engine down immediately

if the oil pressure value does not read 5 psi (34 kPa) within five seconds. 4. Check the oil sender. To identify corrective action, refer to the troubleshooting section of the engine

operators manual provided with the unit.

LOW COOLANT LEVEL SHUTDOWN

1. Allow the engine to cool. 2. Check the coolant level in the radiator. To access the radiator cap, you must remove the access panel

from the top of the enclosure directly above the radiator. Add coolant until it is 3/4 in. (1.9 cm) below the filler neck. Secure the radiator cap back into its original position.

3. Inspect coolant hoses, engine block and water pump for visible leaks. 4. Check the engine oil to verify no coolant has mixed with it (oil will appear milky if coolant is present).

Consult the engine operators manual for additional information.

HIGH COOLANT TEMPERATURE SHUTDOWN

1. Check the coolant level in the overflow jug. 2. Restart the engine and read the coolant temperature to verify a high coolant temperature shutdown. Stop

the engine immediately if the coolant temperature is 230F (110C) or more. 3. Allow the engine to cool. Add coolant to the overflow jug if it is low and then check the level of coolant

in the radiator. To access the radiator cap, you must remove the access panel from the top of the enclosure directly above the radiator. Add coolant until it is 3/4 in. (1.9 cm) below the filler neck. Secure the radiator cap back into its original position.

4. Check the radiator shroud and ducting for blockage and remove any foreign matter. 5. Inspect coolant hoses, engine block and water pump for visible leaks. 6. Check the tension of the serpentine drive belt for the water pump. 7. If no other problems are found, remove the load on the generator and restart the engine. Check the

coolant temperature and shut the engine down immediately if it starts to overheat. Consult the engine operators manual for additional information on engine overheating.

OVERCRANK SHUTDOWN

1. Check the fuel level in the tank. 2. Check for proper operation of the fuel pump. 3. Check the air filter for blockage. 4. If the engine will not start, consult the engine operators manual for additional information on trouble-

shooting starting problems.

OVERSPEED OR UNDERSPEED SHUTDOWN

1. Disconnect all loads and restart the generator. Read the frequency (Hz) on the LCD display. With no loads on the generator, the frequency should read 60.0 Hz.

2. If the frequency is above or below 60.0 Hz, the engine speed will have to be adjusted. Refer to the engine operators manual for throttle adjustments on mechanical governed units and see the electronic governor manual for electronically controlled units.

28

GENERATOR OUTPUT CONNECTION LUGS

The generator is equipped with connection lugs, located behind the lug box door next to the customer convenience receptacles. 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.

WARNING It is HIGHLY RECOMMENDED that only a trained and licensed electrician perform any wiring and related connections to the generator. Installation should be in compliance with the National Electric Code (NEC) as well as any local or state guidelines as required by law. Failure to follow proper installation requirements may result in equipment or

property damage, personal injury or death.

WARNING Before any connections are made to the generator, make sure that the main circuit

breaker and the engine start switch are in the OFF/O position and that the negative (-) battery cable is disconnected. Potentially lethal voltages may be present at the

generator connection lugs.

DANGER IMPROPER OR INCORRECT CONNECTIONS TO A BUILDINGS ELECTRICAL SYSTEM CAN CAUSE POTENTIALLY LETHAL VOLTAGES TO BACKFEED IN UTILITY LINES. THIS MAY RESULT IN INJURY OR ELECTROCUTION TO UTILITY WORKERS NEARBY. MAKE SURE THE GENERATOR IS SUPPLING POWER TO AN ISOLATED OBJECT OR

BUILDING THAT IS NOT CONNECTED TO ANY UTILITY LINES.

Connections to the lugs should be made by running the power cables up through the slots in the plastic cable guide at the base of the lug box. DO NOT make any connections directly to the lugs. The lug box door is equipped with a safety interlock switch that will automatically trip the main circuit breaker and disable the voltage regulator when the lug door is opened. Use a hex-wrench to tighten the cable connections.

WARNING Never attempt to disable or modify the lug door safety switches. Equipment damage, personal injury or death

may result.

A ground connection is located next to the connection lugs. The unit MUST be connected to a good earthen 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 standby power source. INSTALLA- TION SHOULD BE IN COMPLIANCE WITH NATIONAL ELECTRIC CODE (NEC), AS WELL AS ANY STATE AND LOCAL CODES OR REGULATIONS.

VOLTAGE SELECTOR SWITCHES

The voltage selector switches are located on a panel attached to the generator behind the door located next to the fuel tank filler. One selector switch is a three position switch that changes the connections between the generator output leads and the connection lugs on the main control panel. The other selector switch is a two position switch that changes the resistance to the voltage regulator to set the generator output voltage to 480V or 600V. Voltage ranges are selected by rotating the handles on the switches to the desired voltage.

NEVER CHANGE THE VOLTAGE SELECTOR SWITCHES WHILE THE ENGINE IS RUNNING. This will cause severe arcing and damage to the switches and generator windings.

L1 L2 L3 N

Run Cables Through Slots

29

The three position selector switch must be at 480/277V when the two position selector switch is at or switching to 600V.

Each voltage selector switch is equipped with a locking mechanism. Once the proper voltage has been selected, push the red latch on the inside of the phase switch handle up and insert a padlock through the handle. By locking the handle in place, you will prevent unauthorized personnel from changing the switch settings.

Note: UNITS WITHOUT A CONVENIENCE RECEPTACLE BUCK TRANSFORMER AND NOT AT 600V: When the voltage selector switch is in position for 480/277V 3, voltage at the two GFCI duplex convenience receptacles is 139 volts and the voltage at the two twist-lock receptacles is 240/139 volts. When the voltage selector switch is in position for 208/120V 3, voltage at the two twist-lock receptacles and the two GFCI receptacles is 208/120 volts.

Unit Configuration

Switch Configuration Voltage Configuration

600/348V 3-Phase

480/277V 3-Phase

208/120V 3-Phase

240/120V 1-Phase

208 120

480 277

600V 480V

T1 L1

T4 T7

T10

N

T2

L2

T8 T5

T9 T6

T3

L3

T11T12

L-N

L-L

L1 - L2 = 600V L1 - N = 348V L2 - L3 = 600V L2 - N = 348V L3 - L1 = 600V L3 - N = 348V N =

208 120

480 277

600V 480V

T1 L1

T4 T7

T10

N

T2

L2

T8 T5

T9 T6

T3

L3

T11T12

L-N

L-L

L1 - L2 = 480V L1 - N = 277V L2 - L3 = 480V L2 - N = 277V L3 - L1 = 480V L3 - N = 277V N =

208 120

240 120

480 277

600V 480V

T4

T7

T10

T1

L1

L2T8

T2T9

T3

T6 T11

L3

T5T12 N

L-N

L-L

L1 - L2 = 208V L1 - N = 120V L2 - L3 = 208V L2 - N = 120V L3 - L1 = 208V L3 - N = 120V N =

208 120

240 120

600V 480V T10 T7

T6 T8

T12 T2 T11T3

T4 T1

T5T9L3 N

L1

120V120V

240V

L1 - L3 = 240V L2 - N = ------- L1 - N = 120V L3 - N = 120V

30

CAUTION The two120V GFCI receptacles should not be used in the 480/277 and 600/348 voltage

settings and the three 240V twist-lock receptacles should not be used in the 600/348 voltage setting as the voltage will be higher and equipment damage could result.

4-POSITION VOLTAGE SELECTOR SWITCH OPTION

The voltage selector switches are located on a panel attached to the generator behind the door located next to the fuel tank filler. One selector switch is a four position switch that changes the connections between the generator output leads and the connection lugs on the main control panel. The other selector switch is a two position switch that changes the resistance to the voltage regulator to set the generator output voltage to 480V or 600V. Voltage ranges are selected by rotating the handles on the switches to the desired voltage.

NEVER CHANGE THE VOLTAGE SELECTOR SWITCH WHILE THE ENGINE IS RUN- NING! This will cause severe arcing and damage to the switches and generator windings.

The four position selector switch must be at 480/277V when the two position selector switch is at or switching to 600V.

Unit Configuration

Switch Configuration Voltage Configuration

348/600V 3-Phase

277/480V 3-Phase

600V 480V

OR

T1 L1

T4 T7

T10

N

T2

L2

T8 T5

T9 T6

T3

L3

T11T12

L-N

L-L

L1 - L2 = 600V L1 - N = 348V L2 - L3 = 600V L2 - N = 348V L3 - L1 = 600V L3 - N = 348V N =

600V 480V

OR

T1 L1

T4 T7

T10

N

T2

L2

T8 T5

T9 T6

T3

L3

T11T12

L-N

L-L

L1 - L2 = 480V L1 - N = 277V L2 - L3 = 480V L2 - N = 277V L3 - L1 = 480V L3 - N = 277V N =

31

Each voltage selector switch is equipped with a locking mechanism. Once the proper voltage has been selected, push the red latch on the inside of the switch handle up and insert a padlock through the handle. By locking the handle in place, you will prevent unauthorized personnel from changing the switch settings.

Note: UNITS WITHOUT A CONVENIENCE RECEPTACLE BUCK TRANSFORMER AND NOT AT 600V: When the voltage selector switch is in position for 277/480V 3, voltage at the two GFCI duplex convenience receptacles is 139 Volts and the voltage at the three twist-lock receptacles is 139/240 volts. When the voltage selector switch is in position for 120/208V 3, voltage at the two GFCI duplex convenience receptacles is 120 volts and the voltage at the three twist-lock receptacles is 120/208 volts. When the voltage selector switch is in position for 120/240 3 (DELTA), voltage at the two GFCI duplex convenience receptacles is 120 volts and the THREE TWIST-LOCK RECEPTACLES SHOULD NOT BE USED. When the voltage selector switch is in position for 120/240V 1, voltage at the two GFCI duplex convenience receptacles is 120 volts and the voltage at the three twist-lock receptacles is 120/240 volts.

120/208V 3-Phase

120/240V 3-Phase

120/240V 1-Phase

Unit Configuration

Switch Configuration Voltage Configuration

600V 480V

OR T4

T7

T10

T1

L1

L2T8

T2T9

T3

T6 T11

L3

T5T12 N

L-N

L-L

L1 - L2 = 208V L1 - N = 120V L2 - L3 = 208V L2 - N = 120V L3 - L1 = 208V L3 - N = 120V N =

600V 480V

OR

L1 - L2 = 240V L1 - N = 120V L2 - L3 = 240V L2 - N = 208V L3 - L1 = 240V L3 - N = 120V N =

600V 480V

OR T10 T7

T6 T8

T12 T2 T11T3

T4 T1

T5T9L3 N

L1

120V120V

240V

L1 - L3 = 240V L2 - N = ------- L1 - N = 120V L3 - N = 120V

32

CAUTION The two120V GFCI receptacles should not be used in the 480/277 and 600/348 voltage

settings and the three 240V twist-lock receptacles should not be used in the 600/348 voltage setting as the voltage will be higher and equipment damage could result.

EMERGENCY STOP SWITCH

The generator is equipped with one EMERGENCY STOP switch, located on the rear corner of the unit next to the control panel door. The switch is clearly labeled with EMERGENCY STOP and is red. The switch can be accessed and activated with all doors closed and locked.

Activate the EMERGENCY STOP switch by pushing the red button in until it locks down. This will trip the main circuit breaker which will open the contact disconnecting the load to the connection lugs. This will also open the fuel circuit, shutting down the engine. The Emer- gency Stop fault will be displayed on the LCD.

The switch will remain closed until it is pulled out.

Use the EMERGENCY STOP switch only when the generator must be shut down imme- diately. For any other shut down, refer to Shutting Down on page 23.

MAIN CIRCUIT BREAKER

The main circuit breaker is located on the main control panel. When the breaker is in the OFF/O position, power is interrupted between the customer connection lugs and the generator. Once the connections have been made to the connection lugs and the generator has been started and allowed to reach normal operating temperature, the breaker may be switched to the ON/I position.

The main circuit breaker will be tripped, disconnecting power to the connection lugs if any of the following items occur while the unit is running:

1. Overload of the generator circuits to the connection lugs (208/120V only). 2. The door covering the customer connection lugs is opened. 3. If the EMERGENCY STOP switch is activated.

Make sure any problems that cause the main circuit breaker to trip are corrected before returning the switch to the ON/I position.

WARNING The main circuit breaker interrupts power to the customer connection lugs only! The customer convenience receptacles have power even if the main circuit breaker is in the OFF/O position. To disconnect power to the convenience receptacle, use the

individual circuit breakers located near each receptacle.

GENERATOR BOX CIRCUIT BREAKERS

These circuit breakers are located on the generator box near the phase switches. The breakers protect the extra taps (T13 and T14) that go from the generator box to the control box. If one of these breakers were to open, the generator would not output 600V when 600V is selected. This is because the voltage regulator wouldnt be getting any power. However, all the other voltage settings would continue to work.

EM ERGENCY

S T O P

ON I

OFF O

33

VOLTAGE REGULATION

The electronic voltage regulator controls the output of the generator by regulating the current into the exciter field. The regulator has three screwdriver adjustable potentiometers that may be adjusted for voltage, stability and voltage roll-off (U/F). The voltage regulator on the unit is adjusted before shipment from the factory. Contact Magnum Power Products LLC for additional information before attempting to adjust the voltage regulator.

Note: For units equipped with a Marathon DVR2000E+ digital voltage regulator, please refer to the Marathon operating manual provided with the unit.

CUSTOMER CONVENIENCE RECEPTACLES

The generator is equipped with five convenience receptacles. The large receptacles are 240/120VAC twist-lock receptacles rated at 50A each. The smaller receptacles are 120VAC duplex receptacles rated at 20A each with ground fault circuit interrupt (GFCI) protection. These receptacles are not routed through the main circuit breaker. Each receptacle has its own circuit breaker, located directly above or next to the receptacle. Each breaker is sized to the maximum rating of the corresponding receptacle.

Power to the recpetacles is available any time the generator is running, EVEN IF THE MAIN CIRCUIT BREAKER IS OFF/O. MAKE SURE THAT ANY EQUIPMENT CON- NECTED TO THE CONVENIENCE RECEPTACLES IS

TURNED OFF BEFORE TURNING THE BREAKERS ON. Make sure that the voltage selector switches are in the

proper position and that the output voltage is correct for the equipment that is connected to the receptacles. Improper

voltage may cause equipment damage or malfunction.

DERATING FOR ALTITUDE

All generator sets are subject to derating for altitude and temperature; this will reduce the available power for operation of tools and accessories connected to the auxiliary receptacles. Typical reductions in performance are 2-4% for every 1000 ft. (305 m) of elevation and 1% per 10F (-12C) increase in ambient air temperature over 72F (22C).

REMOTE START TERMINAL BLOCK

The remote start terminal block is located just to the right of the three twist-lock convenience receptacles. It provides a connection for installation of a remote start switch which will allow the generator to be started by a remote dry-contact closure switch.

Before pressing the "AUTO" button, verify that the contacts on any remote switch linked to the generator are OPEN. If the contacts on a remote switch are closed, the generator will crank and start when "AUTO" is selected. Attach the switch leads to the two unused terminals on the generators remote start block. For additional information on starting the generator, refer to Manual Starting Of The Generator on page 21.

TRANSFER SWITCH

The generator neutral is bonded to ground when shipped from the factory. The bonding plate will need to be removed when the generator is used as a standby power source. Installation should be in compliance with National Electric Code (NEC), as well as any state and local

codes or regualtions.

CAUTION Do not use 120V GFCI outlets when generator at 480 or 600 volts. Equipment damage or personal injury may result.

CAUTION Do not use 240V twist lock outlets when generator at 600 volts. Equipment damage or personal injury may result.

Remote Start

Switch Terminals

34

When the generator is used as a standby power supply, it must be equipped with a transfer switch which isolates it from the utilitys 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. The transfer switch automatically returns the load back to the normal source when power is restored back to operating levels.

DANGER FAILURE TO ISOLATE THE GENERATOR FROM THE NORMAL POWER UTILITY CAN CAUSE POTENTIALLY LETHAL VOLTAGE TO BACKFEED INTO THE UTILITY LINES. THIS MAY RESULT IN INJURY OR ELECTROCUTION OF UTILITY WORKERS NEARBY. MAKE SURE THE GENERATOR IS ISOLATED BY A TRANSFER SWITCH FROM ANY LOCAL UTILITY LINES. THIS ALSO APPLIES IF THE GENERATOR IS BEING USED AS

A BACKUP TO SOME OTHER TYPE OF POWER SUPPLY.

Installation of a transfer switch or other type of remote starting device is the responsibility of the generator user. Installation of such devices must be performed by following all directions supplied by the manufacturer of the switch. If attaching the generator to a power supply normally serviced by a utility company, notify the utility company and check local and state regulations. Familiarize yourself with all instructions and warning labels supplied with the switch.

WARNING ONLY a licensed electrician should perform wiring and 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. Before any connections

are attempted, make sure the main circuit breaker and the engine start switch are in the OFF/O position and that the negative (-) battery cable has been disconnected

from the engine starting battery.

When using the generator as a standby or substitute power supply, make sure the output voltage and phase rotation of the generator match those of the local power utility. Improper

voltage or phase rotation may cause equipment damage or malfunction.

AUTO EXERCISE TIMER

Generators installed in a standby application should be exercised regularly to maintain operating condition and to ensure responsiveness in an emergency situation. The following procedure demostrates how to run (exercise) the generator on a time schedule:

1. Press the PAGE SELECT button until Password appears at the top of the screen. 2. Press the down arrow button until Date/Time is selected and press ENTER. 3. Press the down arrow button until Timer1 Repeat is selected and press ENTER.

Incoming Utility Power

WHITE = Incoming Utility Power

GRAY = Normal Utility Power Circuit BLACK = Emergency Generator Power Circuit

Utility Meter

Transfer Switch

Main Distribution Panel

(Utility Power)

Emergency Distribution Panel (Generator Power)

Power From Generator

35

4. Choose the day or days the unit should run and press ENTER. 5. Press the down arrow button until Timer1 ON Time is selected and press ENTER. 6. Adjust the desired time to start running and press ENTER. 7. Press the down arrow button until Timer1Duration is selected and press ENTER. 8. Adjust the time period to the length of time the unit should run after starting, and press ENTER. 9. Press PAGE SELECT three times to return to the main menu. 10. Press the AUTO button to switch modes to automatic.

Note: The controller must be in AUTO mode to run at the programmed time. Use a trickle battery charger or solargizer to prevent the controller from draining the battery while in AUTO mode.

DAILY WALK AROUND INSPECTION

Failure to perform a daily inspection may result in serious damage to the prime mover.

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. Replace the belt according to the manufacturers recommendations.

Note: At the 500 hour/12 month service interval, it is recommended the belt be removed and checked for wear. While the belt is removed, inspect pulleys and bearings. Rotate and feel for hard turning or unusual sounds. If pulleys or bearings need replacement contact the engine manufacturer.

ENGINE AND GENERATOR MAINTENANCE

Check the engine oil level daily before starting the engine. DO NOT start the generator if the oil level is below the ADD mark on the dipstick. The normal operating level for the engine oil is anywhere 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 the engine operators manual for the proper grade of oil, including special operating conditions such as a change in season or climate.

Check the coolant level daily. The coolant is checked by visually inspecting the level in the coolant overflow jug, located near the radiator. The normal operating level is anywhere between the FULL and ADD markings on the overflow jug, with the optimum level noted as NORMAL RANGE. WHEN THE ENGINE IS STOPPED AND COMPLETELY COOL, coolant may be added directly to the overflow jug. Consult the engine operators manual for coolant recommendations and proper mixture.

Check the condition of the air filter by viewing the level of vacuum draw on the filter minder gauge. Replace the air filter when the yellow center bar reaches the red section on the gauge (20 in. H20).

Poorly maintained equipment can become a safety hazard! In order for the equipment to operate safely and properly over a long period of time, periodic maintenance and occasional repairs are necessary. NEVER perform even routine service (oil/filter changes, cleaning, etc.) unless all electrical components are shut off. When servicing this equipment always follow the instructions listed below.

Make sure the engine start switch is turned to the OFF/O position. Verify all circuit breakers are open (OFF/O). Activate (push in) the EMERGENCY STOP switch. Disconnect the negative (-) terminal on the battery. Attach a DO NOT START sign to the control panel. This will notify everyone the unit is being serviced and

will reduce the chance of someone inadvertently trying to start the unit. If the unit is connected to a remote start or transfer switch, make sure the remote switch is also off and

tagged. Never wash the unit with a high pressure hose or with any kind of power washer. Never wash the engine block or fuel tank with a power washer or steam cleaner. Water may enter the

cabinet and collect in the generator windings or other electrical parts causing damage.

36

If the unit is stored outside, check for water inside the cabinet and generator before each use. If wet, dry the unit thoroughly before starting.

BASIC MAINTENANCE SCHEDULE - JOHN DEERE ENGINE

Refer to the original equipment manufacturers operating manual for a complete list of maintenance requirements. Failure to comply with the procedures as described in the engine

operators manual will nullify the warranty, decrease performance and cause equipment damage or premature equipment failure.

Use the schedule in the following table as a guide for regular maintenance intervals. For additional or replacement copies of the engine operators manual, contact an authorized dealer in your area.

* Replace primary air cleaner when dust valve restriction indicator gauge shows a vacuum of 25 in. H2O.

** Change the oil and oil filter after the first 100 hours, then every 250 hours. If John Deere Plus 50 II engine oil is used, the interval can be increased to every 500 hours.

Item Daily 250 Hrs.

500 Hrs./12 Months

3000 Hrs./ 36 Months

As Required

Check oil level

Check coolant level

Check fuel level

Check tire pressure

Check all electrical connections

Inspect radiator fins for debris, clean as required

Check fuel filter/water separator bowl

Check air cleaner dust valve restriction indicator gauge *

Perform visual walkaround inspection

Change engine oil and replace oil filter **

Check oil vapor recirculation system/non-return valve

Replace oil vapor recirculation filter

Service battery

Replace fuel filter elements

Check engine mounts

Check air intake hoses, connections, and system

Check engine electrical ground connection

Check automatic belt tensioner and belt wear

Check cooling system

Lubricate leveling jack(s)

Check generator drive plate torque (Refer to Checking Generator Drive Plate Torque on page 39)

Test thermostats

Replace air cleaner elements

Replace alternator and fan belts

Check fuses

Add coolant

Bleed fuel system

37

BELT TENSIONERS

John Deere engines use two types of belt tensioners: manual and automatic. Adjust the belt using the manual tensioner according to the manufacturers specifications. The automatic tensioner cannot be adjusted or repaired and is designed to maintain proper tension over the belts life. Units with the automatic belt tensioner must be inspected according to the manufacturers specifications.

LIFTING THE GENERATOR

A central lift point is located on the top of the generator. The central lift point is connected to a lift structure inside the unit. Attach a sling or hook directly to the central lift point only if the devices are in good condition and the equipment being used to raise the unit has sufficient capacity. For approximate weights, refer to the Specifications section pages 9- 10. Always remain aware of others around you when moving or lifting the generator. Keep the cabinet doors closed and locked.

TOWING THE TRAILER

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. Release the jack locking pin and rotate the jack into the travel position. Make sure the locking pin snaps into place.

2. Connect any trailer wiring to the tow vehicle. Check for proper operation of the stop and signal lights.

3. Make sure all doors are closed and secure.

4. Check for proper inflation of the trailer tires. For maximum tire pressures, refer to the Specifications section pages 9-10.

5. Check the wheel lugs, tighten or replace any 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. 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 (67-81 Nm). D. Third pass tighten to 90-120 ft-lbs (122-162 Nm).

Note: After the first road use, re-torque the lug nuts in sequence.

6. Maximum recommended 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.

TRAILER WHEEL BEARINGS

Some trailers are equipped with a grease zerk fitting to allow lubrication of the wheel bearings without the need to disassemble the axle hub. To lubricate the axle bearings, remove the small rubber plug on the grease cap, attach a standard grease gun fitting to the grease zerk fitting and pump grease into the fitting until new grease is visible around the nozzle of the grease gun. Use only a high quality grease made specifically for lubrication of wheel bearings. Wipe any excess grease from the hub with a clean cloth and replace the rubber plug when finished. The minimum recommended lubrication is every 12 months or 12,000 miles (19,312 km). More frequent lubrication may be required under extremely dusty or damp operating conditions.

Central Lift Point

1

2

3

4

5 6

6-Stud Sequence

52

34 1

5-Stud Sequence

38

JACK MAINTENANCE

The following procedures should be performed at least annually.

SIDE-WIND MODELS

The internal gearing and bushings of the jack must be kept lubricated. Apply a small amount of automotive grease to the internal gearing by removing the jack cover, or if equipped, use a needle nose applicator or 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. If equipped, the axle bolt and nut assembly of the caster wheel must also be lubricated with the same light

weight oil.

TOP-WIND MODELS

Apply a lightweight oil to the screw stem.

CHECKING GENERATOR DRIVE PLATE TORQUE

Follow the procedure below to check the torque of the generator drive plate bolts in accordance with the maintenance chart. Refer to Basic Maintenance Schedule - John Deere Engine on page 37.

1. Disconnect the engine starting battery.

2. Remove the generator fan guard.

3. Torque each of the drive plate bolts to the appropriate specification in the table below.

4. Reinstall the generator fan guard. Reconnect the battery.

VISCOUS FAN CLUTCH

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. When the fan is operating at full speed, it will switch to a slower speed when the coolant temperature drops. There will be an audible difference when the engine cooling fan switches speeds. Depending on unit model, the temperature ranges vary between 170F and 200F (77F and 93C).

Unit ft-lbs (Nm)

MMG75CAN6 36 (49)

MMG100CAN6 36 (49)

39

AUXILIARY FUEL TANK OPTION

The auxiliary fuel tank option is designed so the unit can run from an external fuel tank. The unit is still programmed to shut down when the internal tanks fuel level drops below 5%. In order for the unit to run off of an auxiliary tank, the fuel level in the internal tank must remain over 5%. To operate the unit using an auxiliary fuel tank, use the following procedure:

1. Shut down the unit and check that the level of fuel in the tank is above 5%.

2. Attach the auxiliary fuel 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.

FUEL TRANSFER PUMP OPTION

The fuel transfer pump option allows the fuel tank to be refilled from an external bulk fuel source. When the fuel transfer switch is on, anytime the fuel level drops below 15% the fuel transfer pump will begin pumping fuel from an external bulk fuel source into the fuel tank on the unit. The fuel transfer pump will shut off when the fuel level of the internal tank reaches 90%. The pump will also be monitored to ensure a certain percentage increase in fuel level over a given period of time to prevent the pump from running dry. To operate the fuel transfer system, use the following procedure:

1. Shut down the unit.

Note: If the external bulk fuel supply is already connected, the unit does not have to be shut down to turn the fuel transfer pump option on or off.

2. Attach the external bulk fuel supply to the FUEL TRANSFER INLET fitting on the unit.

3. Turn on the fuel transfer switch.

FUEL TRANSFER INLET

40

AC WIRING DIAGRAM - MMG75CAN6

B R

E A

K E

R 24

0V 5

0AB R

N

24 0V

5 0A

B R

E A

K E

R

24 0V

5 0A

B R

E A

K E

R

B LK

B LK

B LK

B LK

B R

N

5 9

13

6 10

14

7 8

11 12

15 16T5

B LK

B LK

PA IR

B LK

G R

N /Y

E L

(T 7)

C T-

3

BRN/WHT

L2 L3

SHUNT

L1

C T-

2 C

T- 1 BLK

G R

N /Y

E L

G R

N /Y

E L

G R

N /Y

E L

PA IR

B LK

PA IR

B LK

1 2 3 4T4

BRN/WHT

G R

O U

N D

TO G

E N

F R

A M

E

L0

60 H

Z 50

H Z

O N

R E

G U

LA TO

R 4

A M

P FU

S E

W H

T

R E

D F

+ F-F+

3 467

B R

N /W

H T

B LK

B LK

F -

B R

N

M E

C H

A N

IC A

L LU

G S

G R

O U

N D

TO FR

A M

E

B LK

B LK

50 A

24 0V

R C

P T.

B LK

G FC

I R

E C

P T

12 0V

17 21

25

18 22

26

19

20

23 24

27 28

T9

R C

P T.

24 0V

50 A

50 A

R C

P T.

24 0V

B LK

B LK

B LK

T6 T8 T1 0

T1 1

T7 T1 T1 2

T2 T3

G E

N E

R AT

O R

F+ F-

12 0V

20 A

B R

K E

R

12 0V

R E

C P

T G

FC I

L3L2L1L0

S E

35 0

V O

LT A

G E

R E

G U

LA TO

R

12VDC

(T 9)

G R

N /Y

E L

B R

K E

R 20

A 12

0V

G N

D

B K

R D

LU G

D O

O R

N O 1211

S A

FE TY

S W

IT C

H

LT B

LU

LT B

LU

LT B

LU

LT B

LU

LT B

LU

BLK

BLK

PA IR

B LK (L 0)

(3 ) J

U M

M P

E R

W

IR E

S O

N P

H A

S E

S

W IT

C H

1 5-

20 , 1

2- 17

, 10

-2 1

W IR

E S

N O

T U

S E

D IN

B

U C

K B

O O

S T

O P

TI O

N

S E

E D

C W

IR IN

G D

IA G

R A

M

M A

IN

C IR

C U

IT

B R

E A

K E

R

P P

N N

T1 4

T1 3

F O

R C

T C

O N

N E

C TI

O N

S

21 P

IN

C O

N N

1

B R

E A

K E

R 1

0A B

R E

A K

E R

1 0A

21

43

2 4

3 01

7 8

6

21 P

IN

C O

N N

2 P P N

N R

D /V

IB K

/W T

L L K

K

R D

/V I

M TB

P IN

1

RD/OR

BN/WT

R D

/O R

R D

/O R

BN/WT1

BN/WT2 BN2

BN

BN1

Y L

B K

(2 .5

K , 2

W AT

T)

A D

JU S

TM E

N T

V O

LT A

G E

S E

LE C

TO R

S W

IT C

H 60

0 V

O LT

B N

1

B N

/W T1

B N

1

B N

/W T1

(F U

E L)

90 45

5_ O

R G

_0 5.

28 .1

3

41

AC WIRING DIAGRAM - MMG100CAN6

B R

E A

K E

R 24

0V 5

0AB R

N

24 0V

5 0A

B R

E A

K E

R

24 0V

5 0A

B R

E A

K E

R

B LK

B LK

B LK

B LK

B R

N

5 9

13

6 10

14

7 8

11 12

15 16T5

B LK

B LK

PA IR

B LK

G R

N /Y

E L

(T 7)

C T-

3 BRN/WHT

L2 L3

SHUNT

L1

C T-

2 C

T- 1 BLK

G R

N /Y

E L

G R

N /Y

E L

G R

N /Y

E L

PA IR

B LK

PA IR

B LK

1 2 3 4T4

BRN/WHT

G R

O U

N D

TO G

E N

F R

A M

E

L0

M E

C H

A N

IC A

L LU

G S

G R

O U

N D

TO FR

A M

E

B LK

B LK

50 A

24 0V

R C

P T.

B LK

G FC

I R

E C

P T

12 0V

17 21

25

18 22

26

19

20

23 24

27 28

T9

R C

P T.

24 0V

50 A

50 A

R C

P T.

24 0V

B LK

B LK

B LK

T6 T8 T1 0

T1 1

T7 T1 T1 2

T2 T3

G E

N E

R AT

O R

F+ F-

12 0V

20 A

B R

K E

R

12 0V

R E

C P

T G

FC I

L3L2L1L0

12VDC

(T 9)

G R

N /Y

E L

B R

K E

R 20

A 12

0V

G N

D

B LKR E

D

LU G

D O

O R

N O 1211

S A

FE TY

S W

IT C

H

LT B

LU

LT B

LU

LT B

LU

LT B

LU

LT B

LU

BLK

BLK

PA IR

B LK (L 0)

(3 ) J

U M

M P

E R

W

IR E

S O

N P

H A

S E

S

W IT

C H

1 5-

20 , 1

2- 17

, 10

-2 1

W IR

E S

N O

T U

S E

D IN

B

U C

K B

O O

S T

O P

TI O

N

M A

IN

C IR

C U

IT

B R

E A

K E

R

21 P

IN

P LU

G P

P N N

(2 .5

K , 2

W AT

T)

A D

JU S

TM E

N T

V O

LT A

G E

60 H

Z 50

H Z

O N

R E

G U

LA TO

R 4

A M

P FU

S E

W H

T

R E

D F

+ F-F+

3 467

B R

N /W

H T

B LK

B LK

F -

B R

N

S E

35 0

V O

LT A

G E

R E

G U

LA TO

R

S E

E D

C W

IR IN

G D

IA G

R A

M F

O R

C T

C O

N N

E C

TI O

N S

60 0v

P

R IM

A R

Y

P O

W E

R IS

O LA

TI O

N X

FO R

M E

R

24 0v

S

E C

O N

D A

R YH 2

H 1

X 4

X 2

X 3

X 1

B N

O R

BN1

BN/WT1

21

43

2 4

3 01

7 8

6

21 P

IN

C O

N N

2 P P N

N R

D /V

IB K

/W T

L L K

K

R D

/V I

RD/OR

BN/WT

R D

/O R

R D

/O R

BN/WT1

BN/WT2 BN2

BN

BN1

Y L

B K

60 0

V O

LT S

E LE

C TO

R S

W IT

C H

M TB

P IN

1 (F

U E

L)

90 46

1_ O

R G

_0 7.

23 .1

3

42

AC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT

C IR

C U

IT BR

EA KE

R

C AM

LO C

K PA

N EL

G N

D L0

L1 L3

L2

6 5

8

7 2

VO LT

AG E

R EL

AY

H 1

H 3X2

X4 X1

X3 H 2

H 4

BL K

R ED

PO W

ER R

EL AY

BL K

BL K

W H

T

BL K

BU C

K XF

O R

M ER

BLK

7 86

51 2

3 4

C O

M

N C

N O

E3E2E1 YE

L

R EDBL

K

D O

W N

C G

N D

U P

TO T

9

TO T

7 BK R

D

W T

D R

O O

P

AD JU

ST M

EN T

VO LT

AG E

R EM

O TE

D O

W N

U P

BN 43 F+ F-

BKBN /W

T

R D

D VR

2 00

0E +

E1 3

F+ F-

7 6

E3 /4

T9 T7

G EN

F+ F- BN

BR /W

T

BK/WT

BR/WT

RD

BK

WT

BK

BN

(2 .5

K, 2

W AT

T) VO

LT AG

E AD

JU ST

M EN

T

T7 T9

PM 30

0 VO

LT AG

E R

EG U

LA TO

R

L1 L3

L2

BR N

BR N

BR /W

T

O FF

P N

D EU

TS C

H 21

P IN

C O

N N

-1 C

O N

N -2

31 P

IN

D EU

TS C

H

32

O R

F+ F-

C O

N N

-2

21 P

IN

D EU

TS C

H

M 15

D EU

TS C

H 31

P IN

C O

N N

-2 O

R

TO T

8

LU G

D

O O

R N

O N

-P O

W ER

ZO

N E

R EC

O N

N EC

T D

O O

R

PM G

S R

BN BN

BR/WT

D EU

TS C

H 21

P IN

C O

N N

-2

BR /W

T BR

/W T

U SE

D O

N

BR /W

T

C O

N N

-2

31 P

IN

D EU

TS C

H

67

G N

/Y L

W T

R EC

O N

N EC

T D

O O

R

PM G

B V

BN

BR/WT

D EU

TS C

H 21

P IN

C O

N N

-1

BR /W

T

C O

N N

-2

31 P

IN

D EU

TS C

H

67

O R

T7 T9

L1 L3

L2

BR EA

KE R

C IR

C U

IT

G EN

T1 T2 T3 T4 N EU

TR AL

BA R

L1 L2L0T7 T9

BRO R

34 33

SO M

E

M O

D EL

S

33 34

C AM

LO C

K PA

N EL

G N

D L0

L1 L3

L2 AL

T

PO W

ER Z

O N

E C

O N

TR O

L O

N LY

39 40

LU G

D

O O

R N

O N

-P O

W ER

ZO

N E

PO W

ER Z

O N

E C

O N

TR O

L O

N LY

3940

N O

N -P

O W

ER ZO

N E

U SE

D O

N SO

M E

M O

D EL

S

N O

N -P

O W

ER ZO

N E

WHT

WHT

N O

TE : R

EP EA

T AL

T C

AM L

O C

K FO

R T

H IR

D S

ET .

S R

D EU

TS C

H 21

P IN

C O

N N

-2

O R

U SE

D O

N M

M G

18 5

AN D

L O

W ER

U SE

D O

N M

M G

23 5

H IG

H ER

AN D

B V

D EU

TS C

H 21

P IN

C O

N N

-1

AN D

H IG

H ER

M M

G 23

5 U

SE D

O N

O R

O R

M M

G 18

5 U

SE D

O N

L O

W ER

AN D

N O

T C

O N

N EC

TE D

T O

T7 &

T 9

FO R

V -F

LE X

C O

N N

EC T

TO 6

00 V

R EL

AY P

IN 4

C O

N N

EC T

TO 6

00 V

R EL

AY P

IN 4

N O

T C

O N

N EC

TE D

T O

T9 F

O R

V -F

LE X

V- FL

EX O

N LY

C O

N N

EC T

TO 6

00 V

R EL

AY P

IN 8

38 37

PO W

ER Z

O N

E C

O N

TR O

L 7 6

SE E

PO W

ER ZO

N E

O PT

IO N

WT

BK

PO W

ER Z

O N

E VO

LT AG

E AD

JU ST

O PT

IO N

TO T

7

TO 1

20 V

BR EA

KE R

S

PM G

D VR

BU C

K TR

AN SF

O R

M ER

C AM

L O

C KS

D ED

IC AT

ED 24

0V G

EN

TO G

EN V

O LT

L 3

TO G

EN V

O LT

L 1

TO L

U G

BL O

C K

G R

O U

N D

TO L

U G

BL O

C K

G R

O U

N D

TO L

0 TO

L 0

90 41

5_ K_

07 .2

3. 13

43

DC WIRING DIAGRAM

TO G

N D

B A

R

TO G N

D B

A R

TO G N

D B

A R

B A

R G

N D

TO

TO G

N D

B A

R

TO G

N D

B A

R

TO G N

D B

A R

TO G

N D

B A

R

P LU

G L

O C

AT IO

NR P

M

P IN

R P

M IN

R P

M G

N D

M A

G IN

M A

G R

E F

D +P

LU G

L O

C AT

IO N

P O

W E

R +

D C

+

R E

LA Y

B O

A R

D

D +

LO W

E R

E S

TO P

B I1

7 P

IN P

LU G

(B IN

A R

Y IN

P U

TS )

B O

1 C

1 +1

2V D

C

LO C

AT IO

N

C O

N TR

O L

P O

W E

R S

W IT

C H

R E

D /B

LK

B LK

R E

D /B

LK

G E

N V

O LT

A G

E

P H

A S

E A

V O

LT A

G E

P H

A S

E B

V O

LT A

G E

P H

A S

E C

V O

LT A

G E

L1

P LU

G L

O C

AT IO

N

N E

U TR

A L

L2 L3 N

P H

A S

E C

C U

R R

E N

T P

H A

S E

B C

U R

R E

N T

P H

A S

E A

C U

R R

E N

T

4 P

IN P

LU G

(G E

N C

U R

R E

N T)

P LU

G L

O C

AT IO

N

L3L2L1

P H

A S

E G

N D

C O

M

P LU

G L

O C

AT IO

N

M D

C C

O N

TR O

LL E

R

R E

D /V

IO 2

12 V

- +

B AT

TE R

Y

B LK

G R

O U

N D

T O

E N

G IN

E B

LO C

K

B R

N /W

H T

Y E

L/ W

H T

O R

G /W

H T

G N

/Y L

W H

T O

R N

Y E

L B

R N

G R

Y

W H

T/ V

IO

G R

Y /O

R G

RED

WHT/VIO

B LK

TB 2 1

R E

M O

TE S

TA R

T C

O N

TA C

TS

FU E

L LE

V E

LWHT/VIO

21 -P

IN G

"R U

N "

D E

U TS

C H

RED/VIO

D E

U TS

C H

21 -P

IN J

A LT

. E X

C IT

E

ORN

S TA

R TE

R

F+

RED

2221

N C

W AT

E R

IN FU

E L

IN

O IL

IN

A N

A LO

G IN

P U

TS

P LU

G L

O C

AT IO

N

W H

T

A I1

A I3

A I2

R E

M O

TE S

TA R

T B

I2 B

I3 B

I4 B

I5 B

I6 IN

H IB

IT R

E G

E N

FO R

C E

R E

G E

N

LO W

C O

O LA

N T

C 2

+1 2V

D C

B O

2 S

R T

FU E

B O

3 B

O 4

B O

5 B

O 6

R E

C O

N N

E C

T D

O O

R

O P

E N

O P

E N

O P

E N

B O

2 FU

E L

B O

1 S

TA R

T

C O

M L H

E C

U C

O M

P LU

G L

O C

AT IO

N

E C

U H

3 P

IN P

LU G

E C

U L

S H

IE LD

B LK

G R

Y

D E

U TS

C H

21 -P

IN F

C A

N -S

H LD

C A

N -L

21 -P

IN U

D E

U TS

C HD E

U TS

C H

21 -P

IN V

C A

N -HBLK

S H

IE LD

N O

T C

O N

N E

C TE

D C

U T

B A

C K

A N

D T

A P

E

TO G

E N

F IE

LD

LO W

C

O O

LA N

T

GRY/BLK

BLK

A LT

G R

Y /B

LK

C T-

1

C T-

2

C T-

3

W H

T W

H T

G N

/Y L

B LK

B LK

B LK

S P

LI C

E

O R

LO W

E R

LO W

E R

U P

P E

R

U P

P E

R

LO W

E R

LE FT

S ID

E

R E

D /W

H T

X T

U V

W M

N P

R S

H J

K L

C D

E F

G A

B

GRY

SHLD

BLK

G E

N F-

RED

G E

N F+

RED/WHT

ORN

GRN/YEL

GRY

E -S

TO P

S W

IT C

H

N O

N O

4A 3A

4 3

BLK

RED

RED

F-

BLK

RED

SHLD

GRY

BLK

RED/VIO1

GRY/BLK

BLK

GRY

GRN/YEL

ORN

RED/WHT

ORN

VIO

BLK

O P

E N

P O

W E

R -

D C

-

B O

7 O

P E

N

R E

D /Y

E L

R E

D /W

H T

B I7

O P

E N

RED/BLK

C O

M M

O N

C O

M

Y E

L S

P LI

C E

W H

T

P IN

LO C

AT IO

N

P IN

LO C

AT IO

N

P IN

LO C

AT IO

N

P IN

LO C

AT IO

N

P IN

LO C

AT IO

N

P IN

LO C

AT IO

N

RED

R E

D

TO 4

P O

S P

H A

S E

O P

TI O

N A

L B

AT TE

R Y

D IS

C O

N N

E C

T

TO V

O LT

A G

E

R E

G U

LA TO

R

S W

IT C

H IF

E Q

U IP

P E

D

B LK

M JB

20A BLK BLK

ORN ORG

RED

34 33

RED/WHT

10 1

2 3

4 5

6 7

8 9

RED

ORN

12 11

LU G

D O

O R

S A

FE TY

S W

IT C

H

87

87A 86

30

85

BLK RED/YEL

R E

D

YEL

RED RED/WHT RED/WHT

BLK

S TA

R T

TO G

N D

B A

R

TO V

O LT

A G

E R

E G

U LA

TO R

3

TO 3

P O

S L

U G

B LO

C K

T 7

L3 L2

L1

SHUNT

W T

M A

IN B

R E

A K

E R

L0

S E

E A

C P

R IN

T

S E

E A

C P

R IN

T

X TUVW MNPRS HJKL CDE FG AB

C O

N N

1 C

O N

N 2

B LK

B A

R TO

G N

D O

P TI

O N

A L

H E

AT E

D FU

E L

FI LT

E R

R D

/B K

B K

/W T

B K

/W T

B A

R TO

G N

D FU

E L

S E

N D

E R

G N

D

L1 L2 L3 L0

L1 L2 L3

V O

LT A

G E

S E

N S

E TR

A N

S FO

R M

E R

B R

N Y

E L

O R

N

60 0V

U N

IT S

O N

LY

1432 1 423 3 2 1 4 1 2 3 31

B K

/W T

B LO

C K

1

E -S

TO P

S W

IT C

H B

LO C

K 2

90 20

6_ E

_0 6.

26 .1

3

44

DC WIRING DIAGRAMS FOR OPTIONAL EQUIPMENT

J H

D EU

TS C

H 21

P IN

C O

N N

-2

ED IS

O N

P LU

G

16 /3

BR N

BL U

YE L/

G R

N

FA N

C LU

TC H

R EL

AY

TO C O

N T

BO 7

BO TT

O M

PI N

E ST

O P

BI 1

6 PI

N P

LU G

(B IN

AR Y

IN PU

TS )

PI N

LO C

AT IO

N

LO C

AT IO

N

PL U

G L

O C

AT IO

N

R EM

O TE

S TA

R T

BI 2

BI 3

BI 4

BI 5

BI 6

R EC

O N

N EC

T D

O O

R O

PE N

FU EL

X FE

R E

N AB

LE

LO W

C O

O LA

N T

O PT

IO N

4 PI

N P

LU G

(B IN

AR Y

O U

TP U

TS )

PL U

G L

O C

AT IO

N

BO 3

BO 4

BO 5

BO 6

O PE

N FU

EL X

FE R

O PE

N O

PE N

BO TT

O M

8

. .

1

. .

2

M TB

FU EL

T R

AN SF

ER E

N AB

LE S

W

G R

Y/ VI

O BL

K/ W

H T

G R

Y/ VI

O

R ED

/W H

T

R ED

/V IO

FU EL

TR AN

SF ER

PU M

P

FU EL

X FE

R R

EL AY

TO G

N D

BA R

TO G

N D

BA R

BL K/

W H

T

C O

N N

-2

21 P

IN D EU

TS C

H

13 14 EG

31 P

IN

O R

RD/WT

FU EL

H EA

T R

EL AY

TO G

N D

BA R

BK/WT C O

N N

-2 21

P IN

2524

CA

31 P

IN

O R

FI LT

ER H

EA TE

R

N C

ES TO

P 22

R D

/V I

2A F

U SE

SPLICE

TO G

N D

BA R

BK/WT R D

/B K

C O

N N

-2

21 P

IND EU

TS C

H 2120

XW

31 P

IN

O R

23 22

D EU

TS C

H 31

P IN

C O

N N

-2

O R

C O

N N

-2

BK /W

T

R D

/B K

M M

G 4

05 &

46 5

O N

LY

O R

25 A

FU SE

PI N

LO C

AT IO

N

BI N

AR Y

O U

T

BO 3

BO 4

BO 5

BO 6

BK /Y

L

H IG

H ID

LE R

EL AY

R D

/O R

8 M

TB

R D

/W T

21 P

IN PN

C O

N N

-2 D

EU TS

C H

1. 3K

O H

M

30 0

O H

M 4

PI N

P LU

G

R D

/Y L

WT

R D

BK BK BK BK

WT 6

WT 4

WT 12

WT 8

W T

G Y/

O R

21 P

IN T

C O

N N

-2 D

EU TS

C H

R D

/V I

R D

SP LI

C E

R D

31 P

IN ?

D EU

TS C

H C

O N

N -1

M AY

VA R

Y 7 M TB

10 O

R 1

2 PO

S FU

SE D

P O

W ER

M TB

7 10

O R

1 2

PO S

FU SE

D P

O W

ER

M AI

N P

O W

ER

SW IT

C H

LI G

H T

EN AB

LE

SW IT

C H

D O

O R

S W

IT C

H

PA N

EL L

IG H

T

PA N

EL L

IG H

T

FL IP

H O

O D4

D O

O R

C O

N TR

O L

LI G

H T

LI G

H T

SW IT

C H

IN TE

R IO

R C

AB IN

ET LI

G H

T BK

BA TT

ER Y

C H

AR G

ER - +

BA TT

ER Y

12 V

BLK

RED

BA TT

ER Y

C H

AR G

ER

-

12 V

+

BL K

BA TT

ER Y

D IS

C O

N N

EC T

BA TT

ER Y

D IS

C O

N N

EC T

BA TT

ER Y

FA N

C LU

TC H

G Y/

O R

BK /W

T

TO G

N D

BA R

87 87 A

86

30

85

G Y/

O R

RD/BK

FA N

C LU

TC H

87 87 A

86

30

85

PA N

EL

FU EL

TR AN

SF ER

PU M

P

H EA

TE D

FI LT

ER FU

EL

87 87 A

86

30

8510 M

TB

G Y/

O R

M TB

P IN

1

1

M TB

IN TE

R IO

R

BK

LI G

H T

2 IN

TE R

IO R

LI G

H T

1

R D

/B K

R D

/B K

R D

/B K

SO LA

R PA

N EL

C H

AR G

E M

O D

U LE

-+

BA TT

ER Y

12 V

BL K

R ED

SO LA

R B

AT TE

R Y

C H

AR G

ERH IG

H ID

LE

87 87 A

85

30

86

BO 7

- BO 6

BO 5

BO 4

D ++

R EL

AY B

O AR

D

PL U

G

LA BE

L

R EM

O TE

ST AR

T R

EM O

TE C

O M

M U

N IC

AT IO

N

1 2

3 4

BI 2

SW IT

C H

D ET

EC T

LE AK

FL O

AT

BI 4

(F U

EL )

O R

ES TO

P O

N U

N IT

S U

P TO

M M

G 55

90 41

6_ K_

06 .2

7. 13

C O

M C

O M

C O

M C

O M

N O

N O

N O

N O

+ +

+ +

- -

- -

R EM

O TE

C O

M M

U N

IC AT

IO N

R EL

AY B

O AR

D

1 2

3 4

5 6

12 11

10 9

8 7

1 2

45

WIRING BLOCK DIAGRAM - DEDICATED 12 LEAD GENERATORS OPTION

LO L3

L2 L1

TO C

O N

TR O

L B

O X

LO L3

L2 L1

TO C

O N

TR O

L B

O X

LO L3

L2 L1

TO C

O N

TR O

L B

O X

LO L3

L1 TO

C O

N TR

O L

B O

X

LO L3

L1 TO

C O

N TR

O L

B O

X LO

L3 L2

L1 TO

C O

N TR

O L

B O

X

TO G

E N

E R

AT O

R

48 0/

27 7V

3 P

H H

IG H

W Y

E

20 8/

12 0V

3 P

H L

O W

W Y

E

24 0/

12 0V

3 P

H H

IG H

D E

LT A

12 0V

3 P

H LO

W D

E LT

A 24

0/ 12

0V 1

P H

LO W

Z IG

Z A

G

48 0/

24 0V

1 P

H H

IG H

Z IG

Z A

G

TO G

E N

E R

AT O

R

TO G

E N

E R

AT O

R

TO G

E N

E R

AT O

R TO

G E

N E

R AT

O R

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

T3

T10

T3 T9 T6 T1 T4 T7

T12 T5 T8 T2

T6 T2

T11 T9 T5 T3

T8 T4 T2

T10

T6 T7

T1

T12

T2 T8

T11 T12

T10 T6 T5 T4

T3 T9

T1 T7

L9

L7

L9

L7

L9

L7

L9

L7

T11

TO G

E N

E R

AT O

R

N O

TE :

1. C

A B

LE S

T O

C O

N TR

O L

B O

X M

AY C

O N

TA IN

1 , 2

O R

3 W

IR E

S D

E P

E N

D IN

G O

N T

H E

M O

D E

L A

N D

V O

LT A

G E

. 2.

A P

P LI

E S

T O

A LL

1 2

LE A

D G

E N

E R

AT O

R S

T O

B E

H A

R D

W IR

E D

IN G

E N

B O

X .

90 30

2_ A

_1 1.

06 .1

2

46

TRAILER LIGHTS WIRING DIAGRAM

90387_ORG_10.04.12

G N Y L

B N

W T

GN YL

BN

WT

BN

B N

WT

W T

RIGHT MARKER LAMP

MARKER LAMP

LEFT

TRAILER PLUG

RIGHT TAIL/TURN LAMPLAMP

TAIL/TURN LEFT

LAMP PLATE LICENSE

47

WIRING HARNESS - ELECTRIC BRAKE OPTION

90 28

6_ D

_1 0.

31 .1

2

B AT

TE R

Y

B R

E A

K AW

AY S

W IT

C H

B LU

W H

T B

LK

W H

T W

H T

WHT

WHT

B R

A K

E

BLU

BLUB R

A K

E WHT

B LU

B LU

B LU

B LU

WHT

B R

A K

E

BLU

BLUB R

A K

E WHT

W H

T W

H T

TA N

D E

M A

X LE

W H

T

BLUB R

A K

E WHT

B LU

B LU

WHT

B R

A K

E

BLU

W H

T

TR I-A

X LE

S IN

G LE

A X

LE

48

SERVICE LOG

OIL GRADE AND TYPE: ____________________________ BRAND:___________________________________

COOLANT MIXTURE: ______________________________ BRAND:___________________________________

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49

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