Generac Power Systems MDG25IF4 Owner's Manual
Owner’s Manual
For
Diesel Generator
MDG25IF4
008730
For technical assistance contact:
www.generacmobileproducts.com
Technical Support
1-800-926-9768
Register your Generac product at:
WWW.GENERAC.COM
1-888-GENERAC
(1-888-436-3722)
SAVE THIS MANUAL FOR FUTURE REFERENCE
Use this page to record important information about your Mobile Generator
(000394)
WARNING
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
www.P65Warnings.ca.gov/diesel.
(000393a)
WARNING
CANCER AND REPRODUCTIVE HARM
www.P65Warnings.ca.gov.
Record the information found on your unit data label on this
Unit Model Number
Unit Serial Number
Engine Model
Number
Engine Serial
Number
Generator Model
Number
Generator Serial
Number
Date Purchased
page. See
Engine and generator serial numbers are located on separate
data plates affixed to the engine and generator respectively.
When contacting a Generac Mobile Products Authorized
Service Dealer (GMP ASD) about parts and service, always
supply the complete model number and serial number of the
unit.
Operation and Maintenance: Proper maintenance and care of
the generator ensures a minimum number of problems and
keeps operating expenses at a minimum. It is the operator’s
responsibility to perform all safety checks, to verify that all
maintenance for safe operation is performed promptly, and to
have the equipment checked periodically by a GMP ASD.
Normal maintenance, service and replacement of parts are the
responsibility of the owner/operator and, as such, are not
considered defects in materials or workmanship within the
terms of the warranty. Individual operating habits and usage
may contribute to the need for additional maintenance or
service.
Unit and Serial Number Locations.
ii Owner’s Manual for MDG25IF4
Table of Contents
Section 1: Introduction and Safety
Introduction ..................................................................1
Read This Manual Thoroughly ....................................1
How to Obtain Service .................................................1
Safety Rules .................................................................1
Safety Symbols and Meanings ...................................1
General Hazards ...........................................................2
Trailer Hazards .............................................................2
Electrical Hazards ........................................................3
Explosion and Fire Hazards ........................................3
Battery Hazards ............................................................4
Fuel Hazards .................................................................4
Engine Safety ...............................................................4
Operating Safety ..........................................................5
Positioning the Unit .....................................................5
Towing Safety ...............................................................5
Hitch and Coupling ......................................................5
Safe Towing Techniques .............................................5
Reporting Trailer Safety Defects ................................5
Safety and Operating Decals ......................................6
Section 2: General Information
Specifications .............................................................11
Unit Dimensions .........................................................12
Component Locations ...............................................13
Control Panel ..............................................................14
Unit and Serial Number Locations ...........................16
Altitude and Temperature Limitations .....................16
PowerZone® Controller .............................................17
Controller Features and Functions ............................18
Operator Screens ......................................................18
Maintenance Screens ................................................20
Generator Summary ..................................................20
Engine Tab ................................................................20
Generator Tab ...........................................................20
Alarms Tab ................................................................21
Input/Output Tab .......................................................21
Scheduler Tab ...........................................................22
Status Tab .................................................................22
Generator Monitoring ................................................22
Engine Monitoring .....................................................22
PowerZone Controller Information Displays,
Functions, and Reset .................................................22
Voltage Selector Switch ............................................22
Section 3: Operation
Pre-start Checklist ..................................................... 23
Manually Starting the Unit .........................................23
AUTO (Remote) Starting the Unit .............................24
Wet Stacking .............................................................. 25
Cold Weather Operation ............................................25
Using a Booster Battery or Charger (if equipped) ..26
Generator Output Connections ................................ 26
Generator Cam Lock Connections (If Equipped) ....27
Using the Voltage Selector Switch ...........................28
Fine Voltage Adjustment ...........................................28
Voltage Regulator ...................................................... 28
Achieving 240V Three-Phase in 208V Three-Phase
(Parallel Low Wye) Configuration .............................28
Changing Back to 208V Configuration ...................... 29
Customer Convenience Receptacles .......................29
Main Circuit Breaker ..................................................29
Transfer Switch ..........................................................30
AUTO Exercise Timer ................................................ 30
Accessing the Configuration Menu ............................ 30
Set the Controller Clock ............................................ 31
Set the Schedule .......................................................31
Setting Up a Daily Scheduled Run ............................ 31
Set the Unit to AUTO Mode .......................................31
Shutting Down the Unit .............................................31
Emergency Stop Switch ............................................32
Idle Switch .................................................................. 32
Using the ECU Override Switch ................................ 32
Towing the Unit ..........................................................32
Lifting the Unit ............................................................33
Section 4: Maintenance
Emissions Information ..............................................35
Maintenance ...............................................................35
Daily Walk Around Inspection ..................................35
Belt Tensioners ..........................................................35
General Maintenance .................................................35
Owner’s Manual for MDG25IF4 1
Engine Oil Recommendations .................................. 36
Recommended Oil Types ......................................... 36
Coolant Recommendation ........................................ 36
Basic Maintenance Schedule ................................... 36
Engine Break-In Requirements ................................ 37
Resetting Maintenance Alarms ................................ 37
Checking Generator Drive Plate Torque ................. 38
Jack Maintenance ...................................................... 38
Side-Wind Models ..................................................... 38
Top-Wind Models ...................................................... 38
Trailer Wheel Bearings .............................................. 38
Section 5: Troubleshooting
General Troubleshooting .......................................... 39
Section 6: Wiring Diagrams and Service Log
Wiring Diagram - 3 Position AC Box ........................ 41
Wiring Diagram - 4 Position AC Box ........................ 42
Wiring Diagram - Receptacles .................................. 43
Wiring Diagram - Engine Heater ............................... 43
Wiring Diagram - Wiring Buck (If Equipped) ........... 44
Wiring Diagram - Power Zone PMG ......................... 44
Wiring Diagram - Power Zone Control Box ............. 45
Wiring Diagram - Trailer Lights ................................ 46
Wiring Diagram - Brake Wiring ................................. 47
Wiring Diagram - 12V Battery Charger .................... 48
Wiring Diagram - Power Zone Low Oil Level
(If Equipped) ............................................................... 48
Service Log ................................................................ 49
2 Owner’s Manual for MDG25IF4
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.
(000003)
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate 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 use when
maintained properly.
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
If any section of this manual is not understood, contact your
nearest Generac Mobile Products Authorized Service Dealer
(GMP ASD), or contact Generac Mobile Products Technical
Service at 1-800-926-9768 or
www.generacmobileproducts.com
concerns.
The owner is responsible for proper maintenance and safe
use of the equipment. Comply with regulations the
Occupational Safety and Health Administration (OSHA)
has established, or with equivalent standards. Also, verify
that the unit is applied, used, and maintained in accordance
with the manufacturer's instructions and recommendations.
Do nothing that might alter safe application/usage and
render the unit in noncompliance with the aforementioned
codes, standards, laws, and regulations
Save these instructions for future reference. This manual
contains important instructions for the unit that should be
followed during setup, operation and maintenance of the
unit and battery. ALWAYS supply this manual to any
individual that will use this machine.
with any questions or
.
When contacting a GMP ASD about parts and service,
always supply the complete model number and serial
number of the unit from the data decal located on the unit.
Record the model number and serial numbers in the
spaces provided on the inside front cover of this manual.
Safety Rules
The manufacturer cannot anticipate every possible
circumstance that might involve a hazard. The warnings in
this manual, and on tags and decals affixed to the unit are,
therefore, not all inclusive. If using a procedure, work
method or operating technique that the manufacturer does
not specifically recommend, verify it is safe for others. Also
make sure the procedure, work method or operating
technique utilized does not render the equipment unsafe.
Safety Symbols and Meanings
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. Their definitions are as follows:
How to Obtain Service
When the unit requires service or repairs, contact a
Generac Mobile Products Authorized Service Dealer
(GMP ASD) for assistance. Service technicians are
factory-trained for all service needs.
To locat e a GMP ASD, go to:
www.generacmobileproducts.com/parts-service/
find-service
Owner’s Manual for MDG25IF4 1
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.
Introduction and Safety
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
DANGER
Asphyxiation. Do not operate unit without
a properly functioning exhaust system.
Doing so will result in death or serious injury.
(000340)
(000209b)
WARNING
Loss of life. This product is not intended to
be used in a critical life support application.
Failure to adhere to this warning could result
in death or serious injury.
(000107)
WARNING
Hearing Loss. Hearing protection is
recommended when using this machine.
Failure to wear hearing protection could
result in permanant hearing loss.
(000407)
WARNING
Vision loss. Eye protection is required when
operating unit. Failure to wear appropriate eye
protection could result in vision loss or serious
injury.
(000111)
WARNING
Moving Parts. Keep clothing, hair, and
appendages away from moving parts. Failure
to do so could result in death or serious injury.
(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.
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
WARNING
Risk of injury. Do not operate or service this machine
if not fully alert. Fatigue can impair the ability to service
this equipment and could result in death or serious
injury.
(000215)
(000182a)
WARNING
Equipment damage. Only qualified service personnel may
install, operate, and maintain this equipment. Failure to follow
proper installation requirements could result in death, serious
injury, and equipment or property damage.
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.
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)
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.
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)
General Hazards
Trailer Hazards
2 Owner’s Manual for MDG25IF4
Electrical Hazards Lifting Hazards
(000145)
DANGER
Electrocution. In the event of electrical accident,
immediately shut power OFF. Use non-conductive
implements to free victim from live conductor. Apply
first aid and get medical help. Failure to do so will
result in death or serious injury.
(000104)
DANGER
Electrocution. Water contact with a power
source, if not avoided, will result in death
or serious injury.
(000144)
DANGER
Electrocution. Contact with bare wires,
terminals, and connections while generator
is running will result in death or serious injury.
(000152)
DANGER
Electrocution. Verify electrical system is
properly grounded before applying power.
Failure to do so will result in death or serious
injury.
(000123)
DANGER
Electrocution. Turn utility supply OFF before
working on utility connections of the transfer
switch. Failure to do so will result in death or
serious injury.
(000150)
DANGER
Electrocution. Never connect this unit to the electrical
system of any building unless a licensed electrician
has installed an approved transfer switch. Failure to
do so will result in death or serious injury.
WARNING
Explosion. Batteries emit explosive gases.
Always disconnect negative battery cable
first to avoid spark. Failure to do so could
result in death or serious injury.
(000238)
WARNING
Personal injury. Failure to properly connect
lifting cables, chains, or straps could result in
death, serious injury, or property damage.
(000346)
WARNING
Personal Injury. Do not use lifting eye if there
are signs of damage or corrosion. Doing so
could result in death, serious injury, or
property damage.
(000433)
WARNING
Personal Injury. Do not use lifting eye other
than as directed. Doing so could result in
death, serious injury, or property damage.
(000434)
WARNING
Personal Injury. Verify all fasteners are properly
tightened prior to lifting unit. Failure to do so could
result in death, serious injury, or property damage.
(000351)
(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.
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)
(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.
Introduction and Safety
Explosion and Fire Hazards
Owner’s Manual for MDG25IF4 3
Introduction and Safety
(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.
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)
(000192)
DANGER
Explosion and fire. Fuel and vapors are extremely
flammable and explosive. No leakage of fuel is
permitted. Keep fire and spark away. Failure to do
so will result in death or serious injury.
(000174)
DANGER
Risk of fire. Allow fuel spills to completely dry
before starting engine. Failure to do so will
result in death or serious injury.
Battery Hazards
Fuel Hazards
• 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.
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 alerts described in the
engine operator's manual. A copy of this manual was
supplied with the unit when it was shipped from the factory.
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
• DO NOT run engine indoors or in an area with poor
ventilation. Verify engine exhaust cannot seep into
closed rooms or ventilation equipment.
• 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.
• Shut the engine down if any of the following
conditions exist during operation:
• Abnormal change in engine speed.
• Loss of electrical output.
• Equipment connected to the unit overheats.
• Sparking occurs.
• Engine misfires or there is excessive engine/
generator vibration.
• Protective covers are loose or missing.
• Ambient air temperature is above 120°F (49°C).
4 Owner’s Manual for MDG25IF4
Introduction and Safety
(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.
Operating Safety
Positioning the Unit
•
The area immediately surrounding the unit should
be dry, clean, and free of debris.
• If the unit is equipped with a frame grounding stud,
follow any local, state, and National Electrical Code
(NEC) guidelines when connecting.
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.
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
compatible. Verify the coupling is securely fastened
to the vehicle.
• DO NOT tow trailer using defective parts. Inspect
the hitch and coupling for wear or damage.
• Connect safety chains in a crossing pattern under
the tongue.
• Before towing the trailer, verify 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.
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
vehicles and avoid soft shoulders, curbs and
sudden lane changes.
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 LLC.
If NHTSA receives similar complaints, it may open an
investigation; and if it finds that a safety defect exists in a
group of vehicles, it may order a recall and remedy
campaign. However, NHTSA cannot become involved in
an individual problem between you, your GMP ASD, 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.
Owner’s Manual for MDG25IF4 5
Introduction and Safety
Safety and Operating Decals
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 descriptions.
Replace any missing or hard-to-read decals and use care
when washing or cleaning the unit. Decal part numbers
can be found in the parts manual at
www.generacmobileproducts.com.
Table 1-1. Decal Descriptions
ID Description
1 Lifting Point
2 Tie-Down Location
3 Coolant Drain
4 Engine Oil Drain
5 Ultra Low Sulfur Fuel Only
6 Diesel Fuel
7 Towing Instructions
8 Hot Coolant Under Pressure, Hot Surface
9 Do not Open Door with Engine Running
10 Open Upper Door First
11 Electric Shock Hazard
12 Warning
13 Moving Parts
14 Secondary Filter
15 Primary Filter
16 Battery Disconnect
17 Electrical Ground
18 Ground Output Connection
19 Starting and Stopping the Generator
20 Do not Open Door with Engine Running
21 Terminal Connections (Voltage Selector Switch)
22 CAN Lock Connectors
23 Connection Terminal Lugs
24 Remote Start Terminal Connections
25 Circuit Breaker
26 Electrical Backfeed Danger
27 Operating Instructions
28 Read and Understand Owner’s Manual
29 Buttons Below Controller
30 Neutral
31 Neutral Bonded to Frame
6 Owner’s Manual for MDG25IF4
Introduction and Safety
1
11
10
9
8
7
6
5
2
4
3
2
007607
2
2
1
Figure 1-1. Exterior Decals
Owner’s Manual for MDG25IF4 7
Introduction and Safety
007608
12
13
11
13
14
15
16
17
12
Figure 1-2. Interior Decals
8 Owner’s Manual for MDG25IF4
10000023204
NEUTRAL (L0) BONDED TO FRAME
NULLLEITER (L0) AM RAHMEN ANGESCHLOSSEN
NEUTRO (L0) CONECTADO AL BASTIDOR
POSITION NEUTRE
(L0)
LORSQUE FIXÉ AU CADRE
29
28
27
26
24
18
22
21
20
19
007609
23
23
23
25
30
31
Introduction and Safety
Figure 1-3. Control Panel Decals
Owner’s Manual for MDG25IF4 9
Introduction and Safety
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10 Owner’s Manual for MDG25IF4
Section 2: General Information
Specifications
Description Units MDG25DF4
Engine
Make —
Model — 4LE2T
EPA Tier — Tier 4 Final
Rated Engine Power Output hp (kW) 33.5 (25)
Engine Speed rpm 1800
Fuel consumption—100%: Standby / Prime gph (Lph) 2.3 (8.6) / 2.0 (7.4)
Fuel consumption—75%: Standby / Prime gph (Lph) 1.7 (6.5) / 1.6 (6.1)
Fuel consumption—50%: Standby / Prime gph (Lph) 1.2 (4.4) / 1.1 (4.2)
Battery voltage V (quantity per unit) 12 (1)
Battery rating CCA 720
Isuzu
General Information
®
Generator
Make — Marathon Electric
Model — 282PSL1705
Power output 3Ø standby kW (kVA) 25 (31)
Current output 3Ø standby - 480V (208V) A 37 (86)
Power output 3Ø prime kW (kVA) 20 (25)
Current output 3Ø prime - 480V (208V) A 30 (70)
Power output 1Ø standby kW (kVA) 25 (25)
Current output 1Ø standby - 240V A 104
Power output 1Ø prime kW (kVA) 20 (20)
Current output 1Ø prime - 240V A 83
Power Factor kW (kVA) 1 (1Ø) / 0.8(3Ø)
Frequency Hz 60
Weights
Dry weight—skid mounted lb (kg) 1,977 (896)
Operating weight—skid mounted lb (kg) 2,373 (1,076)
Dry weight—trailer mounted lb (kg) 2,246 (1,018)
Operating weight—trailer mounted lb (kg) 2,642 (1,198)
Capacities
Usable fuel gal (L) 48 (181)
Coolant system gal (L) 4.4 (16.7)
Oil qts (L) 11 (10.4)
Maximum run time hours 24
AC Distribution
Circuit breaker size A 125
Owner’s Manual for MDG25IF4 11
General Information
A
B
C
A
B
C
008731
Description Units MDG25DF4
Specifications are subject to change without notice. Refer to the product specification sheet for complete list.
Unit Dimensions
Figure 2-1. Unit Dimensions
AB C
Skid Mounted 35 in (0.89 m) 48 in (1.22 m) 70 in (1.78 m)
Trailer Mounted 53 in (1.35 m) 65 in (1.65 m) 129 in (3.28 m)
12 Owner’s Manual for MDG25IF4
Component Locations
J
008734
C
N
E
D
F
G
H
B
A
I
M
K
L
General Information
Figure 2-2. Component Locations
A Central Lift Point H Alternator
B Fuel Fill I Manual Holder
C Air Filter J Coolant Overflow Container
D Generator (located behind air filter) K Oil Drain
E Battery L Coolant Drain
F Primary Fuel Filter M Control Panel
G Secondary Fuel Filter N Fork Pockets
Owner’s Manual for MDG25IF4 13
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