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Generac Power Systems
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MAGNUM MMG55DF4
Operating Manual
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Generac Power Systems MAGNUM MMG25IF4, MAGNUM MMG55DF4, MAGNUM MMG45IF4, MAGNUM MMG35DF4 Operating Manual

DIESEL GENERATOR
MMG25IF4 • MMG35DF4 MMG45IF4 • MMG55DF4
TM
With Controller
01306
OPERATING MANUAL
Parts manuals available online at www.generacmobile.com
36949 B 02/16
WARNING
CALIFORNIA PROPOSITION 65 WARNING: Diesel engine exhaust and some of its
constituents are known to the state of California to cause cancer, birth defects, and
other reproductive harm. (000004)
WARNING
CALIFORNIA PROPOSITION 65 WARNING: This product contains or emits chemicals known to the state of California to cause cancer, birth defects, and other reproductive
harm. (000005)
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
This manual provides information and procedures to safely operate and maintain the Generac Mobile Products unit. For your own safety and protection from physical injury, carefully read, understand, and observe the safety instructions described in this manual. Keep a copy of this manual with the unit at all times. Additional copies are available from Generac Mobile Products, or can be found at www.generacmobile.com.The information contained in this manual
was based on machines in production at the time of publication. Generac Mobile Products reserves the right to change any portion of this information without notice.
Read all of the manuals included with the unit. Each manual details specific information regarding items such as setup, use and service requirements. An engine operator’s manual provides detailed operation and maintenance procedures for the engine. Additional copies of the engine operator’s manual are available from the engine manufacturer.
DO NOT MODIFY or use this equipment for any application other than for which it was designed.
Only a trained and licensed electrician should perform wiring and connections to unit. Wiring must be in compliance with National Electrical Code (NEC), state and local regulations, as well as Occupational Safety and Health Administration (OSHA) guidelines.
GENERAC MOBILE 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.generacmobile.com
For technical or parts QUESTIONS, please contact the Generac Mobile Products 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
Generac Mobile Products 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: _____________________________________
iii
This Page Intentionally Left Blank
iv

Table of Contents

Introduction............................................................................................................................ iii
Section 1 - Safety
Safety Notes ....................................................................................................................................... 1
Operating Safety................................................................................................................................. 1
Engine Safety ..................................................................................................................................... 2
Service Safety .................................................................................................................................... 2
Towing Safety..................................................................................................................................... 3
Reporting Trailer Safety Defects ........................................................................................................ 3
Safety Symbol Summary .................................................................................................................... 4
Section 2 - General Information
Specifications ..................................................................................................................................... 5
Unit Dimensions .................................................................................................................... 9
Unit Serial Number Locations ......................................................................................................... 10
Component Locations ...................................................................................................................... 11
Control Panel ................................................................................................................................... 12
Power Zone™ Gen Controller ......................................................................................................... 14
Controller Features and Functions ......................................................................................14
Operator Screens ................................................................................................................15
Maintenance Screens.......................................................................................................... 18
Generator Monitoring........................................................................................................... 21
Engine Monitoring................................................................................................................ 21
Controller Information Displays, Functions and Reset ........................................................ 21
Belt Tensioners................................................................................................................................. 22
Section 3 - Operation
Prestart Checklist ............................................................................................................................. 23
Manual Starting of the Unit ............................................................................................................... 23
Auto (Remote) Starting of the Unit ................................................................................................... 24
Derating for Altitude.......................................................................................................................... 25
Generator Output Connection Lugs.................................................................................................. 25
Fine Voltage Adjustment .................................................................................................................. 26
Voltage Selector Switch.................................................................................................................... 27
Voltage Regulation ........................................................................................................................... 28
Customer Convenience Receptacles ............................................................................................... 28
Main Circuit Breaker ......................................................................................................................... 29
Exhaust Filter Cleaning Operations.................................................................................................. 30
Disable Automatic (Auto) Exhaust Filter Cleaning............................................................... 30
Force a Manual Exhaust Filter Cleaning ............................................................................. 30
Enable Exhaust Filter Cleaning ...........................................................................................31
Transfer Switch................................................................................................................................. 31
Auto Exercise Timer ......................................................................................................................... 32
Accessing the Configuration Menu...................................................................................... 32
Set the Controller Clock....................................................................................................... 32
Set the Schedule ................................................................................................................. 33
Set the Unit to Auto Mode ................................................................................................... 33
Shutting Down the Unit..................................................................................................................... 33
Emergency Stop Switch ................................................................................................................... 34
Idle Switch (MMG25I-45I only) ......................................................................................................... 34
Towing the Unit................................................................................................................................. 34
Lifting the Unit................................................................................................................................... 35
v
Section 4 - Maintenance
Emissions Information ...................................................................................................................... 37
Daily Walk Around Inspection........................................................................................................... 37
General Maintenance ....................................................................................................................... 37
Basic Maintenance Schedule - Isuzu Engine ................................................................................... 39
Basic Maintenance Schedule - John Deere Engine ......................................................................... 40
Isuzu Engine Break-In Requirements............................................................................................... 41
John Deere Engine Break-In Requirements..................................................................................... 41
Resetting the Maintenance Alarms................................................................................................... 41
Checking Generator Drive Plate Torque .......................................................................................... 42
Jack Maintenance............................................................................................................................. 43
Side-Wind Models ............................................................................................................... 43
Top-Wind Models ................................................................................................................ 43
Trailer Wheel Bearings ..................................................................................................................... 43
Section 5 - Troubleshooting
Troubleshooting Automatic Shutdown Conditions............................................................................ 45
Low Fuel Level Shutdown ................................................................................................... 45
Low Oil Pressure Shutdown ................................................................................................45
Low Coolant Level Shutdown .............................................................................................. 45
High Coolant Temperature Shutdown .................................................................................45
Section 6 - Wiring Diagrams
AC Wiring - MMG25IF4, MMG45IF4 ................................................................................................ 47
AC Wiring - MMG35DF4, MMG55DF4 ............................................................................................. 48
AC Wiring - 4 Pos. Voltage Selector Switch Option - MMG25IF4, MMG45IF4 ................................ 49
AC Wiring - 4 Pos. Voltage Selector Switch Option - MMG35DF4, MMG55DF4 ............................. 50
AC Wiring Option - Standard Receptacles ...................................................................................... 51
AC Wiring Option - Engine Heater.................................................................................................... 51
AC Wiring Option - Buck Transformer ............................................................................................. 52
AC Wiring Option - PMG .................................................................................................................. 52
DC Wiring ......................................................................................................................................... 53
Trailer Lights Wiring ......................................................................................................................... 54
Wiring Harness - Electric Brake Option ........................................................................................... 55
DC Wiring Option - 12V Battery Charger..........................................................................................56
DC Wiring Option - Low Oil Level..................................................................................................... 56
Section 7 - Options & Accessories
Generator Cam Lock Connections Option........................................................................................ 57
Viscous Fan Clutch Option ............................................................................................................... 58
Service Log ............................................................................................................................ 59
vi

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, WARN­INGS, CAUTIONS, NOTICES and NOTES.
INDICATES A HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN
Indicates a hazardous situation which, if not avoided, could result in death or serious
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
Section 1 - Safety
DANGER
DEATH OR SERIOUS INJURY.
WARNING
injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could 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 unit, be sure you 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 unit. The following points should be practiced at all times:
• The area immediately surrounding the unit should be dry, clean, and free of debris.
• Position and operate the unit on a firm, level surface.
• DO NOT start a unit in need of repair.
• If the unit is equipped with a frame grounding stud, follow any local, state, and National Electrical Code (NEC) guidelines when connecting.
• DO NOT operate the unit on a combustible surface.
• DO NOT operate a unit while tired, distracted, or under the influence of drugs or alcohol.
• Keep all body parts, clothing and other loose items away from moving parts.
• 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.
• Shut the engine down if any of the following conditions exist during operation:
36949 B MMG25I-35D-45I-55DF4 Operating Manual 1
Safety
1. Noticeable change in engine speed.
2. Loss of electrical output.
3. Equipment connected to the unit overheats.
4. Sparking occurs.
5. Engine misfires or there is excessive engine/generator vibration.
6. Protective covers are loose or missing.
7. If the ambient air temperature is above 120°F (49°C).

ENGINE SAFETY

Internal combustion engines present special hazards during operation and fueling. 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 the unit when it was shipped from the factory.
• DO NOT run engine indoors or in an area with poor ventilation unless exhaust hoses are used. Engine exhaust contains carbon monoxide, a deadly, odorless and colorless gas which, if inhaled, can cause nausea, fainting or death. Make sure engine exhaust cannot seep into closed rooms or ventilation equipment.
• DO NOT touch or lean against hot exhaust pipes or engine components.
• DO NOT clean air filter with gasoline or other types of low flash point solvents.
• 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.
• 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.
• DO NOT open the radiator cap or oil drain plug while the engine is running or before the engine has cooled down. Pressurized coolant and hot engine oil can cause severe burns. Allow the unit to cool completely before attempting any service work.
• Keep area around exhaust pipes and air ducts free of debris to reduce the chance of an accidental fire.

SERVICE SAFETY

All service work must be performed by qualified personnel who are familiar with the equipment. Only a qualified electrician should troubleshoot or repair electrical problems occurring in this equipment. Fol­low the safety guidelines described below to prevent hazardous situations which could result in severe injury or death.
• NEVER wash the unit with high pressure hoses, power washers, or steam cleaners. Water may collect in the unit, causing damage to electrical parts.
• 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.
• Replace all missing and hard to read decals. Decals provide important operating instructions and warn of dangers and hazards.
• Before servicing the unit, verify the Control Power switch and circuit breakers are in the OFF (O) position, and the negative (-) terminal on the battery is disconnected. DO NOT perform even routine service (oil/filter changes, cleaning, etc.) unless all electrical components are shut down.
2 MMG25I-35D-45I-55DF4 Operating Manual 36949 B
• DO NOT start the unit under load. The circuit breakers must be in the OFF (O) position when starting the unit in Manual mode. The circuit breakers can be in the ON (I) position only when started in the Auto mode. A transfer switch must be used in the Auto mode to deflect the load upon startup.

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. 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.
• Verify the hitch and coupling on the towing vehicle are rated equal to, or greater than, the trailer's Gross Vehicle Weight Rating (GVWR).
• Check trailer tires for wear and proper inflation.
• DO NOT tow trailer using defective parts. Inspect the hitch and coupling for wear or damage.
• Verify the trailer hitch and the coupling are compatible. Make sure the coupling is securely fastened to the vehicle.
• Verify directional and brake lights on the trailer are connected and working properly.
• Verify wheel lug nuts are present and tightened to the specified torque.
• 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.
Safety
• When towing, maintain extra space between vehicles and avoid soft shoulders, curbs and sudden lane changes. Practice turning, stopping and backing up in an area away from heavy traffic prior to transporting the unit.
• Wipe the coupler clean and apply fresh grease each time the trailer is towed to eliminate squeaking.
• 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.
• 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. 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 or electric surge brakes. Verify proper 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, verify the level in the brake fluid reservoir, if equipped.

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 Generac Mobile Products.
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 an individual problem between you, your dealer, or Generac Mobile Products.
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
36949 B MMG25I-35D-45I-55DF4 Operating Manual 3
Safety
You can also obtain other information about motor vehicle safety from http://www.safercar.gov.

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 online parts manual at www.generacmobile.com. Below is a summary of the intended meanings for the symbols used on the decals.
STOP
Safety alert symbol; used to alert you to potential hazards.
Hot surface(s) nearby.
Dangerous voltage may be present.
Check diesel fuel fill level.
Read and understand the operator’s manual before operating.
Stop engine.
Asphyxiation hazard; operate in well ventilat­ed area.
Burn/scald hazard; pressurized steam.
Anchor/tie down point.
Disconnect battery before servicing.
Unit electrical ground.
Isolate generator to prevent electrocution hazard.
Belt/entanglement hazard; keep body parts clear of this area.
208 120
480 277
Never change phase
240 120
switch position while engine is running.
Do not remove guard.
Fire/explosion hazard; keep open flames away from unit.
Lift here only.
Never change switch position while engine is running.
Battery is disconnected.
Engine running.
Automatic Start.
Force Exhaust Regeneration.
Fan hazard; keep body parts clear of this area.
01879
Figure 1-1. Decal Safety Symbol Summary
4 MMG25I-35D-45I-55DF4 Operating Manual 36949 B
Section 2 - General Information

SPECIFICATIONS

GENERAC MODEL MMG25IF4
Engine
Make/Brand........................................................................................................................... Isuzu
Model .................................................................................................................................... 4LE2TAGV-03
EPA Tier ................................................................................................................................ F4
Horsepower - prime hp (kW) ............................................................................................... 36.2 (27.0)
Horsepower - standby hp (kW) ............................................................................................ 40.2 (30.0)
Operating Speed rpm .......................................................................................................... 1800
Displacement in
Cylinders - qty ....................................................................................................................... 4
Fuel Consumption - 100% prime gph (Lph) ........................................................................ 2.1 (7.8)
Battery Type.......................................................................................................................... 24
Battery Voltage (Quantity per Unit) ....................................................................................... 12V (1)
Battery Rating ....................................................................................................................... 720 CCA
Generator
Make/Brand........................................................................................................................... Marathon Electric
Model .................................................................................................................................... 283PSL1707
Type, Insulation..................................................................................................................... Brushless, H
Generator Set (Engine/Generator)
3Ø - Standby kW (kVA) ....................................................................................................... 26 (32)
Amps - 3Ø Standby 480V (208V) A ..................................................................................... 38 (89)
3Ø - Prime kW (kVA) ........................................................................................................... 23 (29)
Amps - 3Ø Prime 480V (208V) A ......................................................................................... 35 (80)
1Ø - Standby kW (kVA) ....................................................................................................... 24 (24)
Amps - 1Ø Standby - 240V A .............................................................................................. 100
1Ø - Prime kW (kVA) ........................................................................................................... 22 (22)
Amps - 1Ø Prime - 240V A .................................................................................................. 92
Frequency Hz ....................................................................................................................... 60
Power Factor......................................................................................................................... 1 (1Ø), 0.8 (3Ø)
Sound dB(A) 23 ft @ prime ................................................................................................. 66
3
(L) ............................................................................................................. 133 (2.18)
Weights
Dry Weight, Skid Mounted lbs (kg) ...................................................................................... 2430 (1102)
Operating Weight, Skid Mounted lbs (kg) ........................................................................... 3160 (1433)
Dry Weight, Trailer Mounted* lbs (kg) ................................................................................. 2950 (1338)
Operating Weight, Trailer Mounted* lbs (kg) ....................................................................... 3680 (1669)
*Standard trailer only. Consult factory for custom trailer weights.
Capacities
Fuel Tank Volume gal (L) ..................................................................................................... 100 (379)
Usable Fuel Volume gal (L) ................................................................................................. 90 (341)
Coolant (incl. engine) qt (L) ................................................................................................. 18 (17)
Oil (incl. filter) qt (L) ............................................................................................................. 11 (10.4)
Maximum Run Time hrs ...................................................................................................... 42.9
AC Distribution
Circuit Breaker Size .............................................................................................................. 125
Voltage Selection .................................................................................................................. 3 position switch (lockable)
Voltage Regulation................................................................................................................ +/- 0.5%
Voltages Available 1Ø ...........................................................................................................120, 139, 208, 220, 240, 277
Voltages Available 3Ø ...........................................................................................................208, 220, 440, 480
Trailer
Number of Axles.................................................................................................................... 1
Capacity - Axle Rating lbs (kg) ............................................................................................ 5000 (2268)
Tire Size
Brakes................................................................................................................................... Surge
Hitch - Standard .................................................................................................................... 2'' ball
Maximum Tire Pressure psi ................................................................................................. 65
in ........................................................................................................................... 15
Specifications are subject to change without notice.
36949 B MMG25I-35D-45I-55DF4 Operating Manual 5
General Information
GENERAC MODEL MMG35DF4
Engine
Make/Brand........................................................................................................................... John Deere
Model .................................................................................................................................... 3029HFG03
EPA Tier ................................................................................................................................ F4
Horsepower - prime hp (kW) ............................................................................................... 44 (33)
Horsepower - standby hp (kW) ............................................................................................ 48 (36)
Operating Speed rpm .......................................................................................................... 1800
Displacement in
Cylinders - qty ....................................................................................................................... 3
Fuel Consumption - 100% prime gph (Lph) ........................................................................ 2.9 (11.0)
Battery Type.......................................................................................................................... 24
Battery Voltage (Quantity per Unit) ....................................................................................... 12V (1)
Battery Rating ....................................................................................................................... 720 CCA
Generator
Make/Brand........................................................................................................................... Marathon Electric
Model .................................................................................................................................... 284CSL1542
Type, Insulation..................................................................................................................... Brushless, H
Generator Set (Engine/Generator)
3Ø - Standby kW (kVA) ....................................................................................................... 31 (39)
Amps - 3Ø Standby 480V (208V) A ..................................................................................... 47 (108)
3Ø - Prime kW (kVA) ........................................................................................................... 29 (36)
Amps - 3Ø Prime 480V (208V) A ......................................................................................... 43 (100)
1Ø - Standby kW (kVA) ....................................................................................................... 30 (30)
Amps - 1Ø Standby - 240V A .............................................................................................. 125
1Ø - Prime kW (kVA) ........................................................................................................... 27 (27)
Amps - 1Ø Prime - 240V A .................................................................................................. 113
Frequency Hz ....................................................................................................................... 60
Power Factor......................................................................................................................... 1 (1Ø), 0.8 (3Ø)
Sound dB(A) 23 ft @ prime ................................................................................................. 68
3
(L) ............................................................................................................. 177 (2.9)
Weights
Dry Weight, Skid Mounted lbs (kg) ...................................................................................... 3125 (1418)
Operating Weight, Skid Mounted lbs (kg) ........................................................................... 3860 (1751)
Dry Weight, Trailer Mounted* lbs (kg) ................................................................................. 3725 (1690)
Operating Weight, Trailer Mounted* lbs (kg) ....................................................................... 4460 (2023)
*Standard trailer only. Consult factory for custom trailer weights.
Capacities
Fuel Tank Volume gal (L) ..................................................................................................... 100 (379)
Usable Fuel Volume gal (L) ................................................................................................. 90 (341)
Coolant (incl. engine) qt (L) ................................................................................................. 18 (17)
Oil (incl. filter) qt (L) ............................................................................................................. 11 (10.4)
Maximum Run Time hrs ...................................................................................................... 31
AC Distribution
Circuit Breaker Size .............................................................................................................. 125
Voltage Selection .................................................................................................................. 3 position switch (lockable)
Voltage Regulation................................................................................................................ +/- 1%
Voltages Available 1Ø ...........................................................................................................120, 139, 208, 220, 240, 277
Voltages Available 3Ø ...........................................................................................................208, 220, 440, 480
Trailer
Number of Axles.................................................................................................................... 1
Capacity - Axle Rating lbs (kg) ............................................................................................ 6000 (2722)
Tire Size
in ........................................................................................................................... 15
Brakes................................................................................................................................... Surge
Hitch - Standard .................................................................................................................... 2'' ball
Maximum Tire Pressure psi ................................................................................................. 65
Specifications are subject to change without notice.
6 MMG25I-35D-45I-55DF4 Operating Manual 36949 B
General Information
GENERAC MODEL MMG45IF4
Engine
Make/Brand........................................................................................................................... Isuzu
Model .................................................................................................................................... 4LE2XAGV01
EPA Tier ................................................................................................................................ F4
Horsepower - prime hp (kW) ............................................................................................... 57 (42.8)
Horsepower - standby hp (kW) ............................................................................................ 63.7 (47.5)
Operating Speed rpm .......................................................................................................... 1800
Displacement in
Cylinders - qty ....................................................................................................................... 4
Fuel Consumption - 100% prime gph (Lph) ........................................................................ 3.3 (12.5)
Battery Type.......................................................................................................................... 35/55
Battery Voltage (Quantity per Unit) ....................................................................................... 12V (1)
Battery Rating ....................................................................................................................... 720 CCA
Generator
Make/Brand........................................................................................................................... Marathon Electric
Model .................................................................................................................................... 285PSL1700
Type, Insulation..................................................................................................................... Brushless, H
Generator Set (Engine/Generator)
3Ø - Standby kW (kVA) ....................................................................................................... 44 (55)
Amps - 3Ø Standby 480V (208V) A ..................................................................................... 66 (153)
3Ø - Prime kW (kVA) ........................................................................................................... 38 (47)
Amps - 3Ø Prime 480V (208V) A ......................................................................................... 57 (130)
1Ø - Standby kW (kVA) ....................................................................................................... 40 (40)
Amps - 1Ø Standby - 240V A .............................................................................................. 167
1Ø - Prime kW (kVA) ........................................................................................................... 33 (33)
Amps - 1Ø Prime - 240V A .................................................................................................. 138
Frequency Hz ....................................................................................................................... 60
Power Factor......................................................................................................................... 1 (1Ø), 0.8 (3Ø)
Sound dB(A) 23 ft @ prime ................................................................................................. 66
3
(L) ............................................................................................................ 134 (2.2)
Weights
Dry Weight, Skid Mounted lbs (kg) ...................................................................................... 2843 (1290)
Operating Weight, Skid Mounted lbs (kg) ........................................................................... 3580 (1624)
Dry Weight, Trailer Mounted* lbs (kg) ................................................................................. 3363 (1525)
Operating Weight, Trailer Mounted* lbs (kg) ....................................................................... 4100 (1860)
*Standard trailer only. Consult factory for custom trailer weights.
Capacities
Fuel Tank Volume gal (L) ..................................................................................................... 100 (379)
Usable Fuel Volume gal (L) ................................................................................................. 90 (341)
Coolant (incl. engine) qt (L) ................................................................................................. 18 (17)
Oil (incl. filter) qt (L) ............................................................................................................. 12 (11.4)
Maximum Run Time hrs ...................................................................................................... 27
AC Distribution
Circuit Breaker Size .............................................................................................................. 225
Voltage Selection .................................................................................................................. 3 position switch (lockable)
Voltage Regulation................................................................................................................ +/- 0.5%
Voltages Available 1Ø ...........................................................................................................120, 139, 208, 220, 240, 277
Voltages Available 3Ø ...........................................................................................................208, 220, 440, 480
Trailer
Number of Axles.................................................................................................................... 1
Capacity - Axle Rating lbs (kg) ............................................................................................ 5000 (2268)
Tire Size
in ........................................................................................................................... 15
Brakes................................................................................................................................... Surge
Hitch - Standard .................................................................................................................... 2'' ball
Maximum Tire Pressure psi ................................................................................................. 65
Specifications are subject to change without notice.
36949 B MMG25I-35D-45I-55DF4 Operating Manual 7
General Information
GENERAC MODEL MMG55DF4
Engine
Make/Brand........................................................................................................................... John Deere
Model .................................................................................................................................... 3029HFG03
EPA Tier ................................................................................................................................ F4
Horsepower - prime hp (kW) ............................................................................................... 67 (50)
Horsepower - standby hp (kW) ............................................................................................ 74 (55)
Operating Speed rpm .......................................................................................................... 1800
Displacement in
Cylinders - qty ....................................................................................................................... 3
Fuel Consumption - 100% prime gph (Lph) ........................................................................ 3.9 (14.8)
Battery Type.......................................................................................................................... 24
Battery Voltage (Quantity per Unit) ....................................................................................... 12V (1)
Battery Rating ....................................................................................................................... 720 CCA
Generator
Make/Brand........................................................................................................................... Marathon Electric
Model .................................................................................................................................... 286PSL1701
Type, Insulation..................................................................................................................... Brushless, H
Generator Set (Engine/Generator)
3Ø - Standby kW (kVA) ....................................................................................................... 48 (60)
Amps - 3Ø Standby 480V (208V) A ..................................................................................... 72 (167)
3Ø - Prime kW (kVA) ........................................................................................................... 44 (55)
Amps - 3Ø Prime 480V (208V) A ......................................................................................... 66 (153)
1Ø - Standby kW (kVA) ....................................................................................................... 46 (46)
Amps - 1Ø Standby - 240V A .............................................................................................. 192
1Ø - Prime kW (kVA) ........................................................................................................... 42 (42)
Amps - 1Ø Prime - 240V A .................................................................................................. 175
Frequency Hz ....................................................................................................................... 60
Power Factor......................................................................................................................... 1 (1Ø), 0.8 (3Ø)
Sound dB(A) 23 ft @ prime ................................................................................................. 68
3
(L) ............................................................................................................ 177 (2.9)
Weights
Dry Weight, Skid Mounted lbs (kg) ...................................................................................... 3305 (1499)
Operating Weight, Skid Mounted lbs (kg) ........................................................................... 4040 (1833)
Dry Weight, Trailer Mounted* lbs (kg) ................................................................................. 3905 (1771)
Operating Weight, Trailer Mounted* lbs (kg) ....................................................................... 4640 (2105)
*Standard trailer only. Consult factory for custom trailer weights.
Capacities
Fuel Tank Volume gal (L) ..................................................................................................... 100 (379)
Usable Fuel Volume gal (L) ................................................................................................. 90 (341)
Coolant (incl. engine) qt (L) ................................................................................................. 18 (17)
Oil (incl. filter) qt (L) ............................................................................................................. 11 (10.4)
Maximum Run Time hrs ...................................................................................................... 23
AC Distribution
Circuit Breaker Size .............................................................................................................. 225
Voltage Selection .................................................................................................................. 3 position switch (lockable)
Voltage Regulation................................................................................................................ +/- 1%
Voltages Available 1Ø ...........................................................................................................120, 139, 208, 220, 240, 277
Voltages Available 3Ø ...........................................................................................................208, 220, 440, 480
Trailer
Number of Axles.................................................................................................................... 1
Capacity - Axle Rating lbs (kg) ............................................................................................ 6000 (2722)
Tire Size
in ........................................................................................................................... 15
Brakes................................................................................................................................... Surge
Hitch - Standard .................................................................................................................... 2'' ball
Maximum Tire Pressure psi ................................................................................................. 65
Specifications are subject to change without notice.
8 MMG25I-35D-45I-55DF4 Operating Manual 36949 B

Unit Dimensions

General Information
C
BA
A B
Figure 2-1. Unit Dimensions
A (Width) B (Length) C (Height)
MMG25IF4/35DF4/45IF4/55DF4 ­Skid Mounted
MMG25IF4/35DF4/45IF4/55DF4 ­Trailer Mounted
Specifications are subject to change without notice.
39 in. (.99 m) 95 in. (2.41 m) 65 in. (1.65 m)
58 in. (1.45 m) 152 in. (3.81 m) 83 in. (2.11 m)
C
01906
36949 B MMG25I-35D-45I-55DF4 Operating Manual 9
General Information

UNIT SERIAL NUMBER LOCATIONS

See Figure 2-2 for unit ID tag and Vehicle Identification Number (VIN) tag on the unit. Important information, such as the unit serial number, model number, VIN and tire loading information 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 assistance, you may be asked to provide this information.
UNIT ID Tag
Manufactured by Generac Mobile Products, LLC., a subsidiary of Generac Power Systems, Inc.
(920) 361-4442 (800) 926-9768
Country of Origin
Manufacturing Code
1 ph. 1.0PF 3 ph. .8PF 3 ph. 1.0PF
KW
KVA
V
A
Located behind breaker
door underneath breakers
Serial Number
Model
Weight (lbs/kg) RPM/Frequency
Rating
FOR ELECTRICAL EQUIPMENT
ONLY. POUR MATERIAL
ELECTRIQUE SEULEMENT.
209649
Form: SFC626B
Ins. Class
VIN Tag
MANUFACTURED BY/FABRIQUE PAR: Products LLC DATE: 00/0000 GVWR/PNBV: 000KG (0000LBS) COLD INF. PRESS./ PRESS. DE
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.
00000000000000000
V.I. N. /N. I. V.:
Located on opposite side of trailer
Generac Mobile
XXX000
MODEL:
TYPE:
TRAILER
TIRE AND LOADING INFORMATION
RENSEIGNEMENTS SUR LES PNEUS ET LE CHARGEMENT
The weight of cargo should never exceed 0000KG (0000LBS) Le poids du chargement ne doit jamais depasser 0000KG (0000LBS)
SEE OWNER’S MANUAL FOR
ADDITIONAL
INFORMATION
VOIR LE
MANUEL DE
L’USAGER
POUR
PLUS DE
RENSEIGNEMENTS
01028
Figure 2-2. Serial Number Locations
10 MMG25I-35D-45I-55DF4 Operating Manual 36949 B

COMPONENT LOCATIONS

2
General Information
3
12
1
6
13
4
5
7
11
10
9
Figure 2-3. Component Locations
1. Engine exhaust 8. Lug box panel access
2. Radiator access panel 9. Containment drain/fuel drain port
3. Central lift point 10. Receptacle panel
4. Fuel fill 11. Emergency stop
5. Engine and battery access 12. Control access panel
6. Radiator drain port 13. Breaker panel access
7. Engine access
36949 B MMG25I-35D-45I-55DF4 Operating Manual 11
8
01880
General Information

CONTROL PANEL

6
5
4
1
2
Figure 2-4. Control Panel (Rear of Unit)
1. Voltage selector switch 4. Engine idle switch
2. 50/60 Hz switch (optional) 5. Control power switch
3. Fuel transfer pump switch (optional) 6. Power Zone™ controller
3
01881
12 MMG25I-35D-45I-55DF4 Operating Manual 36949 B
General Information
14
13
15
1
2
3
4
5
6
7
2
12
11
10
Figure 2-5. Control Panel (Right Side of Unit)
1. Main circuit breaker 9. Connection lugs (4)
2. Control panel lights (3) 10. Cam lock connection lugs (5) (optional)
3. 50A circuit breakers (3) 11. Connection for optional equipment inlet
4. Service lights switch 12. 120V/240V twist-lock receptacles (3)
5. 20A circuit breakers (2) 13. Connection for battery charger
6. Lug door safety switch 14. 120V GFCI receptacles (2)
7. Remote start terminal block 15. Emergency stop switch
8. Ground connection lug
8
9
01882
36949 B MMG25I-35D-45I-55DF4 Operating Manual 13
General Information

POWER ZONE™ GEN CONTROLLER

The Power Zone™ Gen controller is an auto start controller that monitors the unit and indicates operational status and fault conditions. The controller can be programmed to automatically start or stop based on time schedule, fault condition, or load demand.
The controller constantly monitors vital generator and engine functions for a number of preprogrammed alarm and fault conditions. When a fault condition occurs, the engine can be shut down automatically and the LCD window will show the fault that caused the shut down; to resume operation, the fault condition must be resolved.
This controller also records a history of unit performance which may be viewed at any time and will not be lost when the controller is powered down.
1
11
10
9
8
7
6
5
Figure 2-6. Power Zone™ Gen Controller Layout
1. LCD window 7. Alarm mute button
2. Navigation buttons 8. Voltage screen button
3. Engine start (manual mode) button 9. Generator screen button
4. Engine stop/reset button 10. Engine screen button
5. Control power switch 11. Home screen button
6.
Auto/manual mode button
2
3
4
01907

Controller Features and Functions

Operator Screens

These buttons are used to enter the various operator screens from any other screen. The operator screens consists of four screens: Home ( ), Engine ( ), Generator ( ), and Voltage Adjust ( ). For information about the
GEN
screens, refer to Operator Screens.

Alarm Mute

The Alarm Mute ( ) button silences the audible alarm. Additional action will be required to fully disable the active alarm.
14 MMG25I-35D-45I-55DF4 Operating Manual 36949 B
V
-
+
General Information

Auto/Manual Mode

The Auto/Manual Mode ( ) button is used to change the startup and shutdown modes of the unit. When pressed once, the unit enters Manual mode and when pressed and held for five seconds, the unit enters Auto mode. If in Auto mode, pressing once will return the unit to Manual mode.

Navigation Buttons

These buttons are used to navigate and interact with the Power Zone™ controller screens. Pressing any directional arrow (▲, ►, ▼, ◄) while on any of the operator screens will open the maintenance screens, and navigate the tabs and pages within the maintenance screens. The Enter () button is used to select menus, confirm alarms, and confirm altered settings.

Control Power Switch

Use this switch to start up and shut down the Power Zone™ controller. This switch should not be turned off when the unit is running.

Engine Start

Pressing the Engine Start (I) button while the controller is in Manual mode will start the unit, provided there are no shutdown errors, and the engine satisfies the start status. If the controller is in Auto mode, the Engine Start (I) button has no effect.

Engine Stop/Reset

Pressing the Engine Stop/Reset (O) button will shut down the unit and put the controller into Stop mode, whether in Manual mode or Auto mode.
CAUTION
In case of an emergency, press the emergency stop switch, located on the side of the unit,
to stop the engine immediately. The Engine Stop/Reset (O) button may delay the engine
shutdown if stop faults exist.
To prevent damage to the generator and connected equipment, remove all loads from the
generator by opening all circuit breakers (turn OFF (O)) before pressing the Engine Stop/
Reset (O) button.

The Liquid Crystal Display (LCD)

This window will display the various operator and maintenance screens. By viewing these screens, the operator will be able to monitor both the engine and generator status while the unit is running.

Operator Screens

The operator screens display the most relevant and critical information an operator will need to properly configure and utilize a unit. From these four screens, the operator can access engine, generator and power transmission information necessary to operate the unit under normal conditions.

Home Screen

The Home screen is the default screen of the controller and will display after the controller is powered up and the unit management software is loaded. It displays a live readout of the kW meter, percent of load used (gauge), selected phase, volts and amps being produced by the generator, and the fuel level with time until empty. The controller will automatically return to this screen from any other screen after a period of inactivity.
36949 B MMG25I-35D-45I-55DF4 Operating Manual 15
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