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Magnum MMG 150 Operating Manual

Other manuals for MMG 150: Operating Manual
Manual is about: Diesel

Summary of MMG 150

  • Page 1

    Diesel generator mmg 150 • mmg 170 • mmg 235 operating manual.

  • Page 2: Magnum Products Llc

    2 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...

  • Page 3

    3 table of contents page introduction ................................................................................................................................... 2 table of contents .................................................................................................................

  • Page 4

    4 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. Safety notes this manual contains dangers, warnings, cautions, notices and notes which must be followed to prevent the ...

  • Page 5

    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 s...

  • Page 6

    6 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 c...

  • Page 7

    7 magnum products llc berlin, wi 54923 usa (800) 926-9768 model serial number 000000 kg lbs made in usa trailer id tag manufactured by/fabrique par: magnum products llc gvwr/pnbv: date: cold infl. Press./press. De gonf a froid gawr/pnbe tire/pneu rim/jante kpa(psi/lpc) sgl/dual this vehicle conforms...

  • Page 8

    8 hot surface(s) nearby. Fire/explosion hazard; keep open flames away from unit. Read and understand the supplied operator’s 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 elec...

  • Page 9

    9 specifications 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 reg...

  • Page 10

    10 specifications 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 re...

  • Page 11

    11 specifications 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 re...

  • Page 12

    12 50” 132” 77” 86” 210” 93” 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 deta...

  • Page 13

    13 service locations.

  • Page 14

    14 1 2 3 4 7 8 9 10 11 12 13 15 14 5 6 main control panel features, standard.

  • Page 15

    15 1. Document holder 2. Air filter meter: this gauge shows the condition of the air filter when the engine is running. 3. Magnum digital controller (mdc): see pages 18-19 for additional information. 4. Auxiliary light switches: these switches operate the optional control panel and interior lights. ...

  • Page 16

    16 1 2 3 5 8 9 10 11 12 13 14 16 15 17 18 6 7 engine engine start start engine engine stop stop manual auto alarm cancel fault reset alarm/fault ready/manual ready/auto warning running supplying load operation page select enter diagnostics status control control on on control control off off man aut...

  • Page 17

    17 1. Document holder 2. Air filter meter: this gauge shows the condition of the air filter when the engine is running. 3. Magnum digital controller (mdc): see pages 18-19 for additional information. 4. Auxiliary light switches: operate optional control panel and interior lights. 5. Circuit breaker ...

  • Page 18

    18 the mdc panel consists of five sections, including: the “control on” / “control off” toggle switch and fine voltage adjustment screw; the “operation” keypad; the lcd window; the “diagnostics” keypad; and the “status” light emitting diodes (led’s). The following is a brief summary of the operation...

  • Page 19

    19 • “auto x” 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 faul...

  • Page 20

    20 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...

  • Page 21

    21 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 118 codes. When full, the controller will automatically remove the oldest file. These codes will not be lost when the control power toggle swit...

  • Page 22

    22 generator start up before starting the generator, carefully read over the pre-start check list. Make sure that all of the items are checked before trying to start the generator. This check list applies to both manual and remote starting of the generator. Pre- start check list make sure the contro...

  • Page 23

    23 4. Press the green “engine start” button. The prestart (preheat) screen will be displayed (if equipped) and a countdown will begin from 20 seconds to 0. 5. The starting screen will be displayed. The engine will crank and start running. 6. The running screen will display. Note: it may take a few s...

  • Page 24

    24 10. Once the engine starts it will immediately begin speeding up to a constant 1800 rpm. On units with isochronous engine governing, the engine may hunt or change speeds until operating temperature is reached. After a few minutes of operation, the engine will be warmed up and the lcd window will ...

  • Page 25

    25 magnum digital 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 li...

  • Page 26

    26 magnum digital controller (mdc)- list of possible alarms/descriptions shut down and warning fault conditions and the displayed message are described in the following table: no. Events specification protection type information on binary output available description 1 aniniom sd sd yes shutdown ala...

  • Page 27

    27 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 wrnservicetime wrn no the period for servicing is set by...

  • Page 28

    28 magnum digital controller (mdc) – history the magnum digital controller (mdc) stores a record of each important event into the history file of the controller. The history file seats 118 records. When the history file is full, the oldest records are removed. Adjusting the display back lighting the...

  • Page 29

    29 resetting of the “time to service” reminder the magnum digital controller (mdc) will display the message “wrnservicetime” when the unit is due for maintenance or service. The maintenance or service interval is set at 250 hours of engine running time. Once the unit has been serviced, the “servicet...

  • Page 30

    30 high coolant temperature shutdown 1. Check the coolant level in the overflow jug. 2. Restart the engine and read the coolant temperature to verify high coolant temperature shutdown. Stop the engine immediately if the coolant temperature is 230°f or more. 3. Allow the engine to cool. Add coolant t...

  • Page 31

    31 run cables through slots generator output connection lugs the generator is equipped with connection lugs behind the lug box door located on the lower portion of the control box. The lugs provide connection points for attachment of external loads to the generator. A large decal on the inside of th...

  • Page 32

    32 l1 l2 l3 n (neutral) g (ground) black red blue white green lock lock double cam lock panel single cam lock panel generator cam lock connections (optional) the generator may be equipped with cam lock connections behind the door on the right side of the customer convenience outlets. These receptacl...

  • Page 33

    33 t4 t7 t10 t1 l1 l2 t8 t2 t9 t3 t6 t11 l3 t5 t12 n l-n l-l l1 - l2 = 208v l1 - n = 120v l2 - l3 = 208v l2 - n = 120v l3 - l1 = 208v l3 - n = 120v n = 208 120 240 120 480 277 t1 l1 t4 t7 t10 n t2 l2 t8 t5 t9 t6 t3 l3 t11 t12 l-n l-l l1 - l2 = 480v l1 - n = 277v l2 - l3 = 480v l2 - n = 277v l3 - l1 ...

  • Page 34

    34 4-position voltage selector switch (optional) the optional four position voltage selector switch is located on a panel attached to the generator behind the door located next to the fuel tank filler. The voltage selector is a four position switch that mechanically changes the connections between t...

  • Page 35

    35 link board attached in 480 volt 3Ø position l1 l-n l2 n l3 l-l t1 t9 t11 t7 t10 t4 t12 t8 t3 t6 t2 t5 l1 l-n l2 n l3 l-l t1 t9 t11 t7 t10 t4 t12 t8 t3 t6 t2 t5 link board attached in 208 volt 3Ø position remove all 1/2” nuts changing output voltage (mmg 235 only) the output voltage can be changed...

  • Page 36

    36 st op e m e r g e n c y on/i on/i off/o off/o emergency stop switch the generator is equipped with one emergency stop switch, located on the right rear corner of the unit next to the control door. The switch is clearly labeled “emergency stop” and is red in color. The switch can be accessed and a...

  • Page 37

    37 customer convenience outlets the generator is equipped with five convenience outlets. The large outlets are 240/120 vac twist-lock receptacles rated at 50 a each. The smaller outlets are 120 vac duplex receptacles rated at 20 a each with ground fault interrupt (gfci) protection. These receptacles...

  • Page 38

    38 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 transfer switch when the ge...

  • Page 39

    39 warning it is strongly recommended that only a licensed electrician perform any wiring and any related connections to the generator. Installation should be in compliance of the national electric code (nec) as well as any state or local codes or regulations. Failure to follow these procedures coul...

  • Page 40

    40 engine break-in requirements note: during the first 20 hours of operation, avoid long periods of no load or sustained maximum load operation. If the generator is to run for longer than five minutes without a load, shut the generator down. The engine is supplied with engine break-in oil from the f...

  • Page 41

    41 central lift eye 1 2 3 4 5 6 6-stud sequence 5 2 3 4 1 5-stud sequence 8 -stud sequence 1 2 3 4 5 6 7 8 lifting the generator a large central lifting eye is located on the top of the generator. The eye is connected to a central lifting frame inside the unit. Attach a sling or hook directly to the...

  • Page 42

    42 trailer plug amber marker lamp amber marker lamp amber marker lamp amber marker lamp red marker lamp identification light bar plate lamp red marker lamp stop-turn signal lamp (left) stop-turn signal lamp (right) fender fender trailer wiring diagram.

  • Page 43

    43 blk blu green yellow brown white break awa y s w + ba tt - t o brakes right turn/st o p left turn/st op t a il/marker ground electric brake wiring harness.

  • Page 44

    44 breaker 240v 50a brn 240v 50a breaker 240v 50a breaker blk blk blk blk brn 59 13 6 10 14 7 8 11 12 15 16 t5 blk blk p a ir blk grn/yel (t7) ct -3 brn/wht l2 l3 shunt l1 ct -2 ct -1 blk grn/yel grn/yel grn/yel p a ir blk p a ir blk 1 2 3 4 t4 brn/wht (2.5k, 2 w a tt) adjustment v o lta g e ground ...

  • Page 45

    45 brn 240v 50a breaker 240v 50a breaker blk blk brn 59 13 6 10 14 7 8 11 12 15 16 t5 blk blk grn/yel (t7) ct -3 brn/wht l2 l3 shunt l1 ct -2 ct -1 breaker blk blk blk grn/yel grn/yel blk blk 1 2 3 4 t4 brn/wht (2.5k, 2 w a tt) adjustment vol t age com l1 ground t o gen frame ct1 ct2 ct common ct3 g...

  • Page 46

    46 breaker 240v 50a 240v 50a breaker 240v 50a breaker blk 10ga blk 10ga blk 10ga blk 10ga blk 10ga blk 10ga 800a l t blu 10ga grn/yel 10ga (t7) ct -3 l2 l3 shunt l1 ct -2 ct -1 breaker qty 3 blk 3/0 qty 3 blk 3/0 qty 3 blk 3/0 grn/yel 14ga grn/yel 10ga grn/yel 10ga p a ir blk 6ga p a ir blk 6ga (2.5...

  • Page 47

    47 breaker 240v 50a 240v 50a breaker 240v 50a breaker blk 10ga blk 10ga blk 10ga blk 10ga blk 10ga blk 10ga 800a l t blu 10ga grn/yel 10ga (t7) ct -3 lug door safety switch brn/wht 14ga l2 l3 shunt 12 11 l1 ct -2 ct -1 breaker grn/yel 14ga grn/yel 10ga grn/yel 10ga p a ir blk 6ga p a ir blk 6ga brn/...

  • Page 48

    48 plug loca tion 2 pin plug (rpm) pin rpm in rpm gnd mag in mag ref d+ plug loca tion p in power + dc + rela y board d+ bott om pin e st op bi1 7 pin plug (binar y inputs) bo1 c1 +12vdc loca tion loca tion loca tion control power switch rd/bk blk rd/bk large 4 pin plug (gen vol t age) phase a vol t...

  • Page 49

    49 plug loca tion 2 pin plug (rpm) pin rpm in rpm gnd mag in mag ref d+ plug loca tion pin power + dc + rela y board d+ bott om pin e st op bi1 6 pin plug (binar y inputs) bo1 c1 +12vdc loca tion loca tion loca tion control power switch rd/bk blk rd/bk large 4 pin plug (gen vol t age) phase a vol t ...

  • Page 50

    50 service log oil grade and type: ____________________________ brand:___________________________________ coolant mixture: ______________________________ brand:___________________________________ __________________________________________________________________________________________ _____________...

  • Page 51

    51 notes __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________...

  • Page 52

    Rev: d (wd) part no: 26277 03.25.09.