Breathing diesel engine exhaust exposes you
to chemicals known to the State of California
to cause cancer and birth defects or other
reproductive harm.
• Always start and operate the engine in a
well-ventilated area.
• If in an enclosed area, vent the exhaust to
the outside.
• Do not modify or tamper with the exhaust
system.
• Do not idle the engine except as necessary.
For more information go to
Engine and Heater Shutdown ...................................15
Owner’s Manual for Indirect Fired Heateriii
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ivOwner’s Manual for Indirect Fired Heater
Section 1: Introduction and Safety
(000100a)
WARNING
Consult Manual. Read and understand manual
completely before using product. Failure to
completely understand manual and product
could result in death or serious injury.
(000001)
DANGER
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
(000002)
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
Introduction and Safety
Introduction
Thank you for purchasing a Generac Mobile Products
LLC product. This unit has been designed to provide
high-performance, efficient operation, and years of quality use when maintained properly.
The MAC1.2G indirect fired heater is designed and built
for sustained, reliable heat production in industrial operating conditions and environments. The MAC1.2G is built
to withstand frequent handling under these conditions.
The unit is mounted on a trailer that has forklift access
and chain attach points on both sides. The fully enclosed
design protects the operating components, allowing allweather storage and operations.
The information in this manual is accurate based on
products produced at the time of publication. The manufacturer reserves the right to make technical updates,
corrections, and product revisions at any time without
notice.
Read This Manual Thoroughly
• Mining
• Construction
• Agricultural applications
• Employee locker areas and housing
• Emergency thawing
• Pre-warming of equipment and motors
• Offshore drilling rigs
• Painting and coating locations
• Airline hanger heat
• Dehumidification
Using this machine for applications other than its
intended purpose may void the warranty. Examples of
misuse include, but are not limited to, using the machine:
• To transport persons or equipment.
• As a tow vehicle.
• As a ladder or work surface.
• During extreme weather.
• Indoors.
• If it is incorrectly serviced or maintained.
If any section of the manual is not understood, contact
your nearest Generac Mobile Products (GMP) Authorized Service Dealer (ASD), or contact Generac Mobile
Products Customer Service at 800-926-9768, or visit
www.generacmobileproducts.com with any questions
or concerns.
The owner is responsible for proper maintenance and
safe use of the unit. The manufacturer strongly recommends that all users read the owner’s manual and thoroughly understand all instructions before using this unit.
The manufacturer also strongly recommends instructing
other users to properly start and operate the unit. This
prepares them if they need to operate the unit in an
emergency.
SAVE THESE INSTRUCTIONS for future reference. This
manual contains important instructions for the unit that
should be followed during placement, operation, and
maintenance of the unit and its components. Always supply this manual to any individual that will use this unit.
Safety Rules
The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The alerts in this
manual, and on tags and decals affixed to the unit, are
not all inclusive. If using a procedure, work method, or
operating technique that the manufacturer does not specifically recommend, verify that it is safe for others and
does not render the equipment unsafe.
Throughout this publication, and on tags and decals
affixed to the unit, DANGER, WARNING, CAUTION, and
NOTE blocks are used to alert personnel to special
instructions about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe
them carefully. Alert definitions are as follows:
Intended Applications
The machine is designed for industrial use. Examples of
intended applications include, but are not limited to:
• Gas and oil exploration
• Utilities and power plants
Owner’s Manual for Indirect Fired Heater1
Introduction and Safety
(000003)
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Asphyxiation. Running engines produce
carbon monoxide, a colorless, odorless,
poisonous gas. Carbon monoxide, if not
avoided, will result in death or serious injury.
(000103)
DANGER
Personal injury. Do not operate unit during transport.
Doing so could result in death, serious injury, or
property damage.
(000231a)
WARNING
(000111)
WARNING
Moving Parts. Keep clothing, hair, and
appendages away from moving parts. Failure
to do so could result in death or serious injury.
CAUTION
(000291)
Equipment damage. Do not attempt to start or operate
a unit in need of repair or scheduled maintenance.
Doing so could result in serious injury, death, or
equipment failure or damage.
WARNING
(000108)
WARNING
Hot Surfaces. When operating machine, do not
touch hot surfaces. Keep machine away from
combustibles during use. Hot surfaces could
result in severe burns or fire.
(000107)
WARNING
Hearing Loss. Hearing protection is
recommended when using this machine.
Failure to wear hearing protection could
result in permanant hearing loss.
CAUTION
(000229)
Equipment or property damage. Do not block air
intake or restrict proper air flow. Doing so could
result in unsafe operation or damage to unit.
CAUTION
(000240a)
Unit damage. Do not stop engine before heating
unit is cooled. Doing so could result in unit damage.
(000105)
DANGER
Explosion and Fire. Fuel and vapors are
extremely flammable and explosive. Add fuel
in a well ventilated area. Keep fire and spark
away. Failure to do so will result in death
or serious injury.
(000214)
DANGER
Explosion and Fire. Do not fill fuel tank past full line.
Allow for fuel expansion. Overfilling may cause fuel
to spill onto engine causing fire or explosion, which
will result in death or serious injury.
NOTE: Notes contain additional information important to
a procedure and will be found within the regular text of
this manual.
These safety alerts cannot eliminate the hazards that
they indicate. Common sense and strict compliance with
the special instructions while performing the action or
service are essential to preventing accidents.
How to Obtain Service
When the unit requires servicing or repairs, contact a
GMP ASD for assistance. Service technicians are factory-trained and are capable of handling all service
needs. For assistance locating a dealer, go to https://
When contacting a GMP ASD about parts and service,
always supply the complete model and serial number of
the unit as given on the data decal located on the unit.
Record the model and serial numbers in the spaces provided on the front cover of this manual.
General Hazards
Explosion and Fire Hazards
2Owner’s Manual for Indirect Fired Heater
Battery Hazards
(000143)
DANGER
Explosion and Fire. Fuel and vapors are extremely
flammable and explosive. Store fuel in a well
ventilated area. Keep fire and spark away. Failure
to do so will result in death or serious injury.
(000147)
WARNING
Risk of Fire. Unit must be positioned in a
manner that prevents combustible material
accumulation underneath. Failure to do so
could result in death or serious injury.
WARNING
Fire risk. Fuel and vapors are extremely
flammable. Do not operate indoors. Doing so
could result in death, serious injury, or
property or equipment damage.
(000281)
WARNING
Explosion and fire risk. Do not smoke near unit.
Keep fire and spark away. Failure to do so could
result in death, serious injury, or property or
equipment damage.
(000282)
WARNING
Personal injury. Trailer must be securely coupled to
the hitch with the chains correctly attached. Uncoupled
or unchained towing could result in death or serious
injury.
(000233a)
(000234a)
WARNING
Crushing hazard. Verify unit is properly secured and
on level ground. An unsecured unit can suddenly roll
or move, causing death or serious injury.
WARNING
Property or Equipment Damage. Tighten wheel lug
nuts after first 50 miles to factory specifications.
Failure to do so could result in death, serious injury,
property or equipment damage.
(000235)
WARNING
Rollover hazard. Unit must be placed on flat, level
ground to prevent tipping or rollover. Failure to do so
could result in death, serious injury, or property or
equipment damage.
(000283)
WARNING
Property or equipment damage. Do not alter the trailer.
Alterations can damage essential safety items. Doing
so could result in death, serious injury, or property or
equipment damage.
(000285)
(000162)
WARNING
Explosion. Do not dispose of batteries in a fire. Batteries
are explosive. Electrolyte solution can cause burns and
blindness. If electrolyte contacts skin or eyes, flush with water
and seek immediate medical attention.
(000163a)
WARNING
Risk of burn. Do not open or mutilate batteries.
Batteries contain electrolyte solution which can
cause burns and blindness. If electrolyte contacts
skin or eyes, flush with water and seek immediate
medical attention.
(000130)
WARNING
Accidental Start-up. Disconnect the negative battery
cable, then the positive battery cable when working
on unit. Failure to do so could result in death
or serious injury.
(000181)
WARNING
Vision Loss. Eye protection is required to avoid
spray from spark plug hole when cranking engine.
Failure to do so could result in vision loss.
WARNING
Environmental Hazard. Always recycle batteries at an
official recycling center in accordance with all local
laws and regulations. Failure to do so could result in
environmental damage, death or serious injury.
(000228)
Introduction and Safety
Trailer Hazards
Owner’s Manual for Indirect Fired Heater3
Always recycle batteries in accordance with local laws
and regulations. Contact your local solid waste collection
site or recycling facility to obtain information on local
recycling processes. For more information on battery
recycling, visit the Battery Council International website
at: http://batterycouncil.org
Introduction and Safety
CAUTION
(000419)
Personal injury. Wear appropriate personal protective
equipment at all times while operating and servicing
unit. Failure to do so could result in personal injury.
Service Safety
• DO NOT perform even routine service (oil/filter
changes, cleaning, etc.) unless all electrical components are shut down.
• Replace all missing and hard to read decals.
Decals provide important operating instructions
and warn of dangers and hazards.
Towing Safety
Towing a trailer requires care. The trailer and vehicle
must be in good condition and securely fastened to each
other to reduce the possibility of an accident. Some
states require that large trailers be registered and
licensed. Contact your local Department of Transportation (DOT) office to verify license requirements for your
particular unit.
Hitch and Coupling
•
Verify the hitch and coupling on the towing vehicle
are rated equal to, or greater than, the trailer’s
Gross Vehicle Weight Rating (GVWR).
• Verify the trailer hitch and the coupling are compat-
ible. Verify the coupling is securely fastened to the
vehicle.
• DO NOT tow the trailer using defective parts.
Inspect the hitch and coupling for wear or damage
before every tow.
• To eliminate squeaking, wipe the coupler clean and
apply fresh grease each time the trailer is towed.
• Connect safety chains in a crossing pattern under
the tongue.
• Before towing the trailer, verify 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.
• Verify all access doors on the trailer are closed and
locked.
Safe Towing Techniques
•
Practice turning, stopping, and backing up in an
area away from heavy traffic prior to transporting
the unit.
• Maximum recommended speed for highway towing
is 45 mph (72 km/h). Recommended off-road towing speed is 10 mph (16 km/h) or less, depending
on terrain.
• When towing, maintain extra space between vehi-
cles and avoid soft shoulders, curbs, and sudden
lane changes.
• Reduce speed before curves, and maintain speed
throughout the curve.
• Reduce speed before going over bumps or holes.
Keep your foot off the accelerator while going over
bumps or holes.
Reporting Trailer Safety Defects
If you believe your trailer has a defect which could cause
a crash, injury, or death, you should immediately inform
the National Highway Traffic Safety Administration
(NHTSA) in addition to notifying Generac Mobile Products, LLC.
If NHTSA receives similar complaints, it may open an
investigation. 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 an
individual problem between you, your dealer, or Generac
Mobile 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.
Running Lights
•
Verify directional and brake lights on trailer are
connected and working properly.
4Owner’s Manual for Indirect Fired Heater
Safety and Operating Decals
008975
4
3
2
1
5
6
7
3
See Figure 1-1. This unit features numerous safety and
operating decals. These decals provide important operating instructions and warn of dangers and hazards. The
following diagrams illustrate decal locations and descrip-
Introduction and Safety
tions. Replace any missing or hard-to-read decals and
use care when washing and cleaning the unit. Decal part
numbers can be found in the unit parts manual at
Risk of poisoning. Do not use mouth to siphon
coolant. Doing so will result in death or serious
injury.
CAUTION
(000323)
Engine damage. Use approved coolant only.
Failure to do so could result in equipment damage.
(000168)
DANGER
Explosion and Fire. Fuel and vapors are
extremely flammable and explosive. Keep fire
and spark away. Failure to do so will result
in death or serious injury.
(000204)
DANGER
Explosion and Fire. Do not overfill fuel tank.
Overfilling may cause fuel to leak and ignite
or explode, resulting in death or serious injury.
WARNING
Personal injury. Trailer must be securely coupled to
the hitch with the chains correctly attached. Uncoupled
or unchained towing could result in death or serious
injury.
(000233a)
WARNING
Property or Equipment Damage. Tighten wheel lug
nuts after first 50 miles to factory specifications.
Failure to do so could result in death, serious injury,
property or equipment damage.
(000235)
WARNING
Property or equipment damage. Do not alter the trailer.
Alterations can damage essential safety items. Doing
so could result in death, serious injury, or property or
equipment damage.
(000285)
Emissions
The United States Environmental Protection Agency (US
EPA) (and California Air Resources Board (CARB), for
engines/equipment certified to California standards)
requires that this engine/equipment complies with
exhaust and evaporative emissions standards. Locate
the emissions compliance decal on the engine to determine applicable standards. For emissions warranty information, please reference the included emissions
warranty. It is important to follow the maintenance specifications in the manual to ensure that the engine complies
with the applicable emissions standards for the duration
of the product’s life.
Engine Oil Recommendations
Change oil and oil filter at least once every 12 months,
even if the hours of operation are fewer than the otherwise recommended service interval. See the applicable
engine manual for recommended oil types. Use only
approved oil types.
For more information, see the engine manual.
Coolant Recommendation
Fuel System
The heater is designed to operate with diesel fuel.
IMPORTANT NOTE: Comply with all laws regulating
the storage, handling, and transporting of fuels.
Follow these guidelines:
• Use only ultra-low-sulfur diesel fuel.
• When temperatures are at or below freezing, use
No. 1D diesel fuel.
• When temperatures are above freezing, use No.
2D diesel fuel.
• In some areas of the country, climatized fuel—a
mixture of 1D and 2D—may also be used.
For more information, see the engine manual.
Use demineralized or distilled water for best results. Hard
water causes scale deposits, which reduces cooling efficiency and raises internal temperatures, possibly leading
to engine damage.
See the engine manual for recommended coolants.
Use a Long Life Coolant Antifreeze or Extended Life
Coolant that meets or exceeds these specifications:
• Isuzu Part Number 8-12346-290-0
• ASTM D4985
See the engine manual for recommended coolants.
Test coolant yearly, or every 1,000 hours, whichever
comes first.
For more information, see the engine manual.
Owner’s Manual for Indirect Fired Heater11
Trailer Towing Guidelines
General Information
Personal injury. Do not operate unit during transport.
Doing so could result in death, serious injury, or
property damage.
(000231a)
WARNING
(000234a)
WARNING
Crushing hazard. Verify unit is properly secured and
on level ground. An unsecured unit can suddenly roll
or move, causing death or serious injury.
008962
3
1
2
A
D
C
B
F
G
E
H
Driving a vehicle with a trailer in tow is different than driving the same vehicle without a trailer in tow. Consider the
following:
• It takes longer to get up to speed.
• More room is needed to turn and pass.
• More distance is needed to stop.
• The driver is responsible for keeping the vehicle
and trailer under control.
When towing, make regular stops to verify the following:
• Coupler is secured to the hitch and locked.
• Electrical connections are made.
• Appropriate slack in the safety chains and the
breakaway switch pull-pin cable.
• Tires are inflated to proper air pressure with no
damage or unusual wear to tread or sidewalls.
• Trailer doors are secured and latched.
Other towing guidelines:
• Use the tow vehicles mirrors to verify there is
enough room for lane changes or entering/exiting
traffic.
• Allow plenty of stopping distance for the trailer and
tow vehicle.
• Do not drive faster than the conditions allow.
• A rule of thumb for passing distance is the distance
with a trailer is four times the passing distance
without a trailer.
• Use lower gears for climbing and descending
grades.
• Do not ride the brakes while descending grades;
this can cause overheating and potential brake failure.
• Do not apply the tow vehicle brakes to correct ex-
treme trailer swaying. Continued pulling of the
trailer, and even slight acceleration, or carefully
applying the trailer brakes (using the electronic
brake controller) will provide a stabilizing force.
Select wheel chock according to equipment type
•
and size.
• Always use in pairs and on firm surfaces.
• Chock in direction of grade.
• Chock both sides of wheel if direction of grade is
unknown.
• Use wheel chock only after parking brake is
applied and tested.
• Center chocks squarely against tread of each
wheel.
• Do not drive over wheel chocks.
Control Panel
The control panel is located in the front compartment of
the unit.
Figure 2-4. Control Panel Features
AEngine control box and ignition
BFuel gauge
CBurner ON/OFF switch
DBlower START push button
EBlower STOP push button
FBlower ON indicator lamp
GBlower OFF indicator lamp
HControl panel main disconnect switch
Wheel Chock Guidelines
12Owner’s Manual for Indirect Fired Heater
Section 3: Operation
(000108)
WARNING
Hot Surfaces. When operating machine, do not
touch hot surfaces. Keep machine away from
combustibles during use. Hot surfaces could
result in severe burns or fire.
(000135)
CAUTION
Engine damage. Verify proper type and quantity of
engine oil prior to starting engine. Failure to do so
could result in engine damage.
(000154)
WARNING
Risk of burns. Do not open coolant system
until engine has completely cooled. Doing so
could result in serious injury.
Asphyxiation. Running engines produce
carbon monoxide, a colorless, odorless,
poisonous gas. Carbon monoxide, if not
avoided, will result in death or serious injury.
(000103)
DANGER
WARNING
Burn hazard. Do not remove ducting until all air
pressure has been emptied from hose duct.
Failure to do so could result in severe injury.
(000288)
Operation
Before Starting Engine
Pre-start Checklist
•
Remove all flammable materials and fire hazards
within 5 ft (1.5 m) of unit.
• Keep unit a minimum of 5 ft (1.5 m) from structures
or barricades.
• Verify the unit is not leaking fluids: inspect inside
and outside the unit for leaking fuel, engine oil,
HTF/hydraulic oil, and engine coolant.
• Verify the following are clear of debris and obstruc-
tions:
– Engine air intake
– Engine exhaust stack
– Outlets and fan intakes
• Verify air duct hose is securely fastened to outlet
duct assembly.
• Check fuel, engine oil, and engine coolant levels.
• Verify unit is properly secure with jacks deployed (if
applicable), wheels chocked, and level.
• Inspect the alternator drive belt for tension and
abnormalities.
• Verify that the burner cover is securely installed.
• Inspect the generator. See the generator manual.
• Verify battery cables are not loose or corroded.
• Inspect ducting for damage or unusual wear.
3.After 10 seconds, remove the oil dipstick and look
at the oil level on both sides. The lower of the two
readings will be the correct oil level measurement.
4.Add oil (if necessary) to adjust the level. After adding or changing the oil, run the engine for one minute before checking the oil level. Wait 10 minutes
to allow the engine to cool and oil to fully drain into
the oil pan.
Typical causes of inaccurate oil level readings:
• Reading the high level of the oil dipstick.
• Reading the oil dipstick before the oil fully drains
into the oil pan.
• Inserting and removing the oil dipstick too quickly.
• The oil dipstick is not fully seated in the oil dipstick
tube.
Engine Coolant Check
Inspect the coolant sub-tank to check the coolant level.
Check the coolant level when the engine is cold, as coolant flows to the sub-tank when the radiator is still hot,
which provides an inaccurate reading. Replace the coolant according to the Maintenance Schedule, or if it is
contaminated or dirty. See Adding Coolant.
Ducting Guidelines
Engine Oil Level Check
NOTE: If engine was running, wait at least 10 minutes
before proceeding.
1.Remove oil dipstick from crankcase and wipe it
clean with a clean, lint free cloth.
2.Slowly insert the clean oil dipstick into the oil dip-
Owner’s Manual for Indirect Fired Heater13
stick tube. Verify the oil dipstick is fully seated.
• Place ducting in desired configuration before oper-
ating the unit.
• Tightly secure ducting end to the unit. Verify any
additional ducting is also tightly secured.
Operation
(000108)
WARNING
Hot Surfaces. When operating machine, do not
touch hot surfaces. Keep machine away from
combustibles during use. Hot surfaces could
result in severe burns or fire.
(000234a)
WARNING
Crushing hazard. Verify unit is properly secured and
on level ground. An unsecured unit can suddenly roll
or move, causing death or serious injury.
CAUTION
(000291)
Equipment damage. Do not attempt to start or operate
a unit in need of repair or scheduled maintenance.
Doing so could result in serious injury, death, or
equipment failure or damage.
WARNING
CAUTION
(000229)
Equipment or property damage. Do not block air
intake or restrict proper air flow. Doing so could
result in unsafe operation or damage to unit.
CAUTION
(000290)
Equipment damage. Do not cover unit during
operation. All ducting ports must remain open
even if not being used. Failure to do so will
result in equipment damage.
008974
ON
OFF
I
O
• Avoid sharp bends or 90° turns in the ducting.
• Use only the necessary length of ducting required;
do not exceed maximum length.
• Verify that ducting is not in a high traffic area, and
will not impede workers or other machinery. Care
should be taken to prohibit the need to step or
climb over ducting.
• DO NOT place ducting over combustible materials.
• DO NOT place ducting over surfaces that may
cause damage or reduce performance, such as
water, sharp rocks or glass, electrical wiring, piping, etc.
• DO NOT place or drape anything over ducting,
such as covers, insulation (insulated ducting is
available), blankets or cloth, or electrical wires.
• Inspect ducting for damage or unusual wear before
each use.
Engine and Heater Startup
1.Turn ignition key to RUN and wait for the light to
expire.
2.Turn ignition key to START.
NOTE: Do not hold the engine starter key in the start
position for more than 15 seconds. Doing so will overheat
the starter motor. Wait 30 seconds for the starter motor to
cool before making a second attempt to start if the engine
fails to start.
3.Warm up engine for 90 seconds.
4.See Figure 3-1. Turn main disconnect switch to
ON.
Figure 3-1. Main Disconnect Switch
5.Press green START button.
6.Turn burner to ON.
7.See Ducting Guidelines. Place heating ducts as
appropriate for the application.
IMPORTANT NOTE: A twisted or bent air duct will
cause loss of air pressure and temperature.
NOTE: Do not use starting aids, such as gasoline. Doing
so will damage the engine.
Adjusting Heater Output
See Thermostat Control to adjust the setpoint (SP) and
differential (dIF). If SP is set to 180 °F (82 °C) and dIF is
set to 10 degrees, the following will happen:
1.Temperature will rise to 180 °F (82 °C).
2.Burner shuts off until temperature cools down 10
degrees.
3.Burner turns back on.
14Owner’s Manual for Indirect Fired Heater
Operation
CAUTION
(000295)
Equipment damage. Shut down the heater before
turning off the generator. Failure to do so could
result in equipment damage.
MENU
F
BIN
003820
A
D
C
B
H
F
E
G
Engine and Heater Shutdown
1.Turn burner switch to OFF.
2.Allow outlet air temperature to cool for at least 90
seconds.
IMPORTANT NOTE: Do not detach ducting until all air
pressure has been emptied from hose duct.
3.Press STOP.
4.Turn ignition key to OFF.
Thermostat
Thermostat Control
1.Press and hold the MENU button until the display
changes to flashing SP.
2.Press the up or down buttons to reach desired
function.
3.Press the MENU button to display current value of
function.
4.Press the up or down buttons until desired value is
reached.
5.Press the MENU button to save. The display will
return to the sensor temperature.
NOTE: If the MENU button is not pressed after changing
the setpoint value, the new value will not be saved.
See the table below for all thermostat functions.
FunctionRange
SP = Setpoint
diF = Differential1 to 30 °F or C5
-30 to 212 °F
(-34 to 100 °C)
Factory
Setting
30
Figure 3-2. Thermostat Features
ATemperature offset indicator
BTemperature units indicator
COperating mode indicator
DLiquid Crystal Display (LCD)
EMENU button
FOutput relay status indicator LED
GDown arrow button
HUp arrow button
ASd = Anti-short
Cycle Delay
OFS = Temperature
Offset
SF = Sensor
Failure Operation
0 to 12 minutes1
0 to 50 °F or C0
0 = output
de-energized
1 = output
energized
1
Changing Temperature Units
The thermostat is factory set to display temperature in
Fahrenheit. Press the up and down buttons simultaneously to convert to Celsius.
Owner’s Manual for Indirect Fired Heater15
Operation
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16Owner’s Manual for Indirect Fired Heater
Section 4: Maintenance
(000139)
WARNING
Risk of burns. Allow engine to cool before
draining oil or coolant. Failure to do so could
result in death or serious injury.
Potential of cancer. Prolonged or repeated contact
with used motor oil has been shown to cause cancer
in laboratory animals. Thoroughly wash exposed
areas with soap and water.
(000127a)
WARNING
(000149)
DANGER
Risk of poisoning. Do not use mouth to siphon
coolant. Doing so will result in death or serious
injury.
Maintenance
Maintenance
Regular maintenance will improve performance and
extend engine/equipment life. Generac Mobile Products,
LLC recommends that all maintenance work be performed by a Generac Mobile Products Authorized Service Dealer (GMP ASD). Regular maintenance,
replacement, or repair of the emissions control devices
and systems may be performed by any repair shop or
person of the owner’s choosing. To obtain emissions control warranty service free of charge, the work must be
performed by a GMP ASD. See the emissions warranty.
Maintenance Tasks
Daily checks must be performed when unit is operated
continuously for extended periods of time. Daily checks
and routine monthly checks can be performed by an
authorized operator.
NOTE: Normal maintenance, service, and replacement
of parts are the responsibility of the owner and are not
considered defects in materials or workmanship within
the terms of the warranty. It is strongly recommended
that equipment be periodically checked by a GMP ASD.
Daily Walk Around Inspection
Inspect for conditions that could hinder performance or
safety, such as (but not limited to) oil, coolant, and fuel
leakage, blocked vents, loose or missing hardware, and
improper electrical connections. Check for foreign matter
blocking vents and on top of unit. Perform any necessary
maintenance tasks. See Trailer Maintenance before
towing.
• Inspect outer cover for significant damage beyond
scuffs and small nicks.
• Inspect for electrical wire abrasion.
• Inspect the fan belt for cracking, fraying, and
stretching. Verify the belt is properly seated in the
pulley grooves. See Maintenance Schedule.
• Check fluid levels.
• Inspect electrical connectors, battery, and ground
points. Look for loose or missing hardware.
• Inspect all flexible rubber hoses for deterioration.
• Inspect hydraulic hoses for signs of wear.
• Verify hoses are not crushed, bent, or twisted.
• Verify there are no cracks or corrosion.
• Inspect tires for unusual wear.
• Inspect ducting for damage or unusual wear.
Draining and Refilling the Oil
1.See Figure 2-2. Place container under the oil drain
hose (I).
2.Remove plug from oil drain hose.
3.See Figure 2-1. Open oil drain valve (H). Drain oil.
4.Close drain valve once draining is complete.
5.See engine manual for oil filter information.
6.See Figure 2-1. Remove filler cap (yellow) (F) on
the rocker arm cover.
7.Fill oil pan to specified level.
8.Replace filler cap.
NOTE: Do not overtighten filler cap. Doing so may dam-
age filler cap.
9.Start engine and let run for five minutes. Verify
there are no leaks.
10. Stop engine and let cool for approximately 10
minutes. Verify oil level is correct. (See Engine Oil
Level Check.) Repeat steps 6–9 until oil is
properly filled.
IMPORTANT NOTE: Do not overfill oil pan. Overfilling
may result in white exhaust smoke, sudden over
engine speed, or engine damage.
Adding Coolant
Owner’s Manual for Indirect Fired Heater17
Maintenance
WARNING
Risk of burns. Contents under pressure.
Do not remove the radiator pressure cap
while engine is hot. Doing so could result
in death or serious injury.
(000322a)
(000154)
WARNING
Risk of burns. Do not open coolant system
until engine has completely cooled. Doing so
could result in serious injury.
(000165a)
CAUTION
Risk of overheating. Do not use any chromate base
rust inhibitor with propylene glycol base antifreeze,
boosters, or additives. Doing so will cause overheating
and possible equipment damage.
CAUTION
(000419)
Personal injury. Wear appropriate personal protective
equipment at all times while operating and servicing
unit. Failure to do so could result in personal injury.
008970
A
008978
B
C
Figure 4-2. Radiator Location
4.Fill radiator slowly with coolant until it reaches the
lip of the filler port.
5.Replace radiator cap.
6.Remove cap (C) from sub-tank.
7.Fill sub-tank with coolant until it reaches the FULL
mark.
8.Replace sub-tank cap.
9.Operate engine approximately five minutes at a
low idle speed to purge air in the coolant system.
Coolant must be changed every year or at 1,000 hours of
operation. Check coolant level and degree of fouling
according to the steps below. Correct coolant level is
approximately 0.39 in (10 mm) below the radiator core
top. Wear proper PPE when handling Long Life Coolant.
1.Verify engine is stopped and cooled.
2.See Figure 4-1. Verify coolant drain plug (A) is
closed.
Figure 4-1. Coolant Drain Plug
3.See Figure 4-2. Remove radiator cap (B).
NOTE: Coolant level will drop.
10. Stop engine and, once cooled, replenish with
coolant until the sub-tank reaches the FULL mark.
Maintenance Schedule
Periodic inspection, service, and maintenance of this unit
is critical to ensuring reliable operation. The following is
the manufacturer’s recommended maintenance schedule. The maintenance items need to be performed more
frequently if the unit is used in severe applications (such
as very high or very low ambient conditions or extremely
dirty or dusty environments). Use the unit hour meter or
calendar time, whichever occurs first, from the previous
maintenance interval to determine the next required
maintenance interval.
NOTE: Some checks are based on hours of operation.
Follow all applicable safety alerts in this manual or the
engine service manual before performing any maintenance checks or service.
This maintenance schedule reflects the minimum tasks
needed to verify the unit remains operational. Some of
the tasks can be performed by an authorized operator,
and others must be performed by a GMP ASD.
NOTE: An authorized operator is one who has been
trained by a GMP ASD in proper operation and
inspection of this unit.
18Owner’s Manual for Indirect Fired Heater
Maintenance
Engine Maintenance Schedule
• Check engine oil level.
• Check fuel level.
• Check engine coolant level.
Daily
50 Hour Break-In
Every 500 Hours
Every 1000 Hours
Every 2000 Hours
Every 3000 Hours
Every 6000 Hours
As Required
1
During the initial operation of a new or rebuilt engine with Break-In Plus, change the oil and filter between a minimum of 100 hours and a
maximum of up to 500 hours.
2
Service intervals depend on sulfur content of the diesel fuel, oil pan capacity, and the oil and filter used.
• Drain water from fuel filters.
• Inspect air cleaner, dust unloader valve, and indicator.
• Perform visual walk around inspection.
• Inspect generator windings for dirty or grime.
• Replace engine oil and engine oil filter.
• Inspect and adjust cooling fan V-belt.
• Drain water from fuel tank.
• Drain oil/water separator.
• Service battery.
• Change engine oil and replace oil filter.
1 2
• Inspect coolant pump.
• Inspect open crankcase vent (OCV) system.
• Remove and replace fuel filter elements.
• Inspect belt wear.
• Inspect belt tensioner.
• Inspect cooling system.
• Pressure test cooling system.
• Check and adjust engine speeds.
• Inspect engine mounts.
• Inspect engine ground connection.
• Inspect generator ball bearings.
• Check the DC no load excitation voltage. See generator manual.
• Inspect crankshaft vibration damper.
• Adjust valve clearance.
• Test glow plugs for continuity.
• Flush and refill cooling system.
• Test thermostat opening temperature.
• Drain water from fuel filters.
• Add coolant.
• Replace air filter element.
• Inspect primary air filter element.
• Replace fan belt.
• Inspect fuses.
• Inspect electrical wiring and connections.
• Purge fuel system.
NOTE: For more information, see engine manual.
Owner’s Manual for Indirect Fired Heater19
Maintenance
(000188)
DANGER
Electrocution. Do not wear jewelry while
working on this equipment. Doing so will
result in death or serious injury.
(000137a)
WARNING
Explosion. Batteries emit explosive gases while charging.
Keep fire and spark away. Wear protective gear when
working with batteries. Failure to do so could result in
death or serious injury.
(000162)
WARNING
Explosion. Do not dispose of batteries in a fire. Batteries
are explosive. Electrolyte solution can cause burns and
blindness. If electrolyte contacts skin or eyes, flush with water
and seek immediate medical attention.
(000163a)
WARNING
Risk of burn. Do not open or mutilate batteries.
Batteries contain electrolyte solution which can
cause burns and blindness. If electrolyte contacts
skin or eyes, flush with water and seek immediate
medical attention.
(000130)
WARNING
Accidental Start-up. Disconnect the negative battery
cable, then the positive battery cable when working
on unit. Failure to do so could result in death
or serious injury.
(000181)
WARNING
Vision Loss. Eye protection is required to avoid
spray from spark plug hole when cranking engine.
Failure to do so could result in vision loss.
WARNING
Environmental Hazard. Always recycle batteries at an
official recycling center in accordance with all local
laws and regulations. Failure to do so could result in
environmental damage, death or serious injury.
(000228)
WARNING
Explosion hazard. Never add acid to a battery.
Add distilled water only. Failure to do so could
result in death, serious injury, or equipment
damage.
(000316)
(000167a)
CAUTION
Equipment damage. Do not make battery
connections in reverse. Doing so will result
in equipment damage.
Battery Inspection
NOTE: Remove the 5 amp controller fuse from control
panel.
An authorized operator should inspect the engine battery
monthly. At this time, the battery fluid level should be
checked using a load tester and distilled water added if
needed. Battery cables and connections should also be
inspected for cleanliness and corrosion.
A GMP ASD should inspect the battery system once
every six months. At this time, the battery condition and
state of charge should be checked using a load test battery. Recharge or replace the battery as required.
Battery service is to be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away.
Observe the following precautions when working on batteries:
• Remove watches, rings, or other metal objects.
• Use tools with insulated handles.
• Wear rubber gloves and boots.
• Do not lay tools or metal parts on top of battery.
• Disconnect charging source prior to connecting or
disconnecting battery terminals.
NOTE: Wash spilled electrolyte down with an acid neutralizing agent. A common practice is to use a solution of
1 lb (454 g) bicarbonate of soda (baking soda) to 1 gal
(3.8 L) of water. Add the bicarbonate of soda solution
until the evidence of reaction (foaming) has ceased.
Flush the resulting liquid with water.
NOTE: Discharge static electricity before touching the
battery by first touching a grounded metal surface.
Battery Installation and Replacement
Always recycle batteries in accordance with local laws
and regulations. Contact your local solid waste collection
site or recycling facility to obtain information on local
recycling processes. For more information on battery
recycling, visit the Battery Council International website
at: http://batterycouncil.org
20Owner’s Manual for Indirect Fired Heater
When required, the battery must be replaced with one of
equivalent size, voltage, and CCA (cold crank amp
capacity). Contact a GMP ASD for correct battery size. A
new battery must be filled with the proper electrolyte and
be fully charged before install.
Battery cables are connected to the unit at the factory.
Proceed as follows to connect cables to battery posts.
Maintenance
1.Connect battery cable from starter contactor to
positive (POS or +) battery post.
2.Connect black battery cable to negative (NEG or -)
battery post.
3.Refer to Engine and Heater Startup.
Other Maintenance Checks
The following inspections should be performed by an
authorized service technician, or a properly trained authorized operator. These maintenance items require a high
level of experience and skill to evaluate and correct.
• Inspect engine accessory drive belts.
• Inspect hoses and connections.
• Inspect fuel supply system.
• Inspect exhaust system.
• Inspect exhaust pipe sleeve.
Trailer Maintenance
Perform daily inspections of the trailer before each use.
• Inspect trailer for damage, such as dents, cracks,
gouges, or deep scratches.
• Inspect trailer for corrosion or abrasion.
• Inspect trailer tires for wear and deflation.
• Inspect all safety devices for damage or unusual
wear.
• Inspect all electrical connections for any bare wires
or other damage.
• Rectify any issues before using the trailer.
Return to Service
Follow the guidelines below for engines and machines
that have not been operated for three to six months:
• Conduct a thorough inspection of the machine
before starting the engine.
• Verify the maintenance schedule is up to date.
• Connect the negative battery cable.
• After starting the engine, let it warm up for more
than 10 minutes at idle.
Short Term Storage
When the machine will not be in use for three or more
months, follow the guidelines below to properly store the
machine:
• Perform all necessary maintenance or repairs
based on the Maintenance Schedule. Perform
any upcoming necessary maintenance task before
storing.
• Fill the fuel tank to FULL.
• Fill coolant to FULL. Do not drain.
• Remove all dirt and debris from inside and outside
the enclosure.
• Lock the machine to prevent any unauthorized
operation.
• Store in a safe location — do not position near or
on top of any combustible materials; observe any
local, state, or national codes or regulations. Store
in a low moisture, low dust area.
• Disconnect the negative cable from the battery.
Owner’s Manual for Indirect Fired Heater21
Maintenance
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22Owner’s Manual for Indirect Fired Heater
Section 5: Troubleshooting
General Troubleshooting Guide
ProblemCauseSolution
Low battery output voltage or discharged
battery.
Loose or corroded connections.Clean and tighten connections.
Engine will not crank
Starter cranks slowly
Hard to start or will not start
Faulty start circuit relay.Contact a GMP ASD.
Blown fuse.Replace fuse.
Faulty main switch or start safety switch.Repair switch as required.
Faulty starter solenoid.Replace solenoid.
Faulty starter.Replace starter.
Low battery output voltage or discharged
battery.
Excessive crankcase oil viscosity.
Loose or corroded connections.Clean and tighten connections.
Engine starting under load.Disengage PTO.
Incorrect starting procedure.
Restricted exhaust.Inspect and correct exhaust restriction.
No fuel.Check fuel tank.
Air in fuel line.Purge fuel lines. See engine manual.
Poor fuel quality.
Water, dirt, or air in fuel system.Drain, flush, fill, and purge fuel system.
Fuel filter restricted or full of water.
Dirty or faulty fuel injectors.
Electronic fuel system failure.
Cold weather.
Excessive crankcase oil viscosity.
Electronic control system problem or basic
engine problem.
Troubleshooting
Charge or replace batteries. See Bat-
tery Inspection.
Charge or replace batteries. See Bat-
tery Inspection.
Drain crankcase oil and replace with
correct viscosity oil. See Draining and
Refilling the Oil.
Review starting procedure. See Pre-
start Checklist and Engine and
Heater Startup.
Drain fuel and replace with proper
grade and quality of fuel for operating
condition.
Replace fuel filter or drain water from
fuel filter.
Contact a GMP ASD.
Use cold weather starting aids (see
engine manual).
Drain crankcase oil and replace with
correct viscosity oil. See Draining and
Refilling the Oil.
Contact a GMP ASD.
Owner’s Manual for Indirect Fired Heater23
Troubleshooting
ProblemCauseSolution
Engine misfiring or runs
irregularly
Lack of engine power
Engine idles poorly
Excessive fuel consumption
Poor fuel quality; incorrect fuel/dirty fuel.Test fuel, drain water from fuel bowl.