Generac Power Systems MDG25IF4 Owner's Manual

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Page 1

Owner’s Manual

For

Diesel Generator

MDG25IF4

008730

For technical assistance contact:

www.generacmobileproducts.com

Technical Support

1-800-926-9768

WWW.GENERAC.COM

1-888-GENERAC

(1-888-436-3722)

SAVE THIS MANUAL FOR FUTURE REFERENCE

Page 2

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

Page 3

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

Page 4

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

Page 5

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.

Page 6

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

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

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

Page 7

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

Page 8

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

Page 9

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

Page 10

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

Page 11

Introduction and Safety

007607

Figure 1-1. Exterior Decals

Owner’s Manual for MDG25IF4 7

Page 12

Introduction and Safety

007608

Figure 1-2. Interior Decals

8 Owner’s Manual for MDG25IF4

Page 13

10000023204

NEUTRAL (L0) BONDED TO FRAME

NULLLEITER (L0) AM RAHMEN ANGESCHLOSSEN

NEUTRO (L0) CONECTADO AL BASTIDOR

POSITION NEUTRE

(L0)

LORSQUE FIXÉ AU CADRE

007609

Introduction and Safety

Figure 1-3. Control Panel Decals

Owner’s Manual for MDG25IF4 9

Page 14

Introduction and Safety

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10 Owner’s Manual for MDG25IF4

Page 15

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

Page 16

General Information

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

Page 17

Component Locations

008734

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

Page 18

General Information

007612

Control Panel

Figure 2-3. Control Panel (rear of unit)

A Voltage Selector Switch E Option

B Emergency Stop Button F Option

PowerZone

Controller

Run/Idle Switch

D Power Switch H Fuel Transfer Pump Switch

14 Owner’s Manual for MDG25IF4

Page 19

General Information

007613

Figure 2-4. Control Panel (right side of unit)

A Main Circuit Breaker I Cam Lock Connection Lugs (5) (if equipped)

B Control Panel Lights (3) J Ground Connection Lug

C 50A Circuit Breakers (2) K Connection Lugs

D Service Lights Switch L Remote Start Terminal Block

E 20A Circuit Breakers (2)

F Lug Door Safety Switch

G 120V GFCI Receptacles (2)

H 120V/240V Twist-Lock Receptacles (2)

Owner’s Manual for MDG25IF4 15

Page 20

General Information

007614

Unit and Serial Number Locations

See Figure 2-5 to locate the unit ID tag (A) and vehicle identification number (VIN) tag (B). Important information such as the unit model number, serial number, VIN, and tire loading information are listed on these tags. Record the information from these tags in the event the tags are lost or damaged. This information may be needed when ordering parts or requesting assistance.

Figure 2-5. Unit and Serial Number Locations

Altitude and Temperature Limitations

All units are subject to derating for altitude and temperature. Derating reduces the available power for operating tools and accessories connected to the outlets. For the MDG25, the engine can provide full prime power up to an altitude of 10,000 ft (3048 m). The maximum air temperature at which the unit can provide full prime power is defined in Table 2-2. If the unit is operated beyond this limit at full power, the coolant temperature will exceed the maximum allowable limit of 235°F (113°C) and cause the engine to shut down.

Table 2-2. Altitude and Temperature Limitations

Model

MDG25

Maximum Altitude

Prime

Power

10,000 ft (3048 m)

Standby

(1371 m)

Power

4500 ft

Maximum Air

Temp erature

111 ° F

(44 °C)

16 Owner’s Manual for MDG25IF4

Page 21

General Information

007615

PowerZone® Controller

The PowerZone 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 shut down automatically and the display screen will show the fault that caused the shut down. The fault condition must be resolved to resume unit operation.

This controller records a history of unit performance, which may be viewed at any time and will not be lost when the controller is powered down.

NOTE: See Controller Features and Functions for descriptions of the callouts below.

Figure 2-6. PowerZone Controller Layout

A Fuel Transfer Pump Switch H Voltage Adjust Button

B Engine Speed Switch I Generator Button

C Navigation Buttons J Engine Button

D Engine START Button K Home Button

E Engine STOP Button L Controller Power Switch

F AUTO or MANUAL Mode Button M N/A

G Alarm Mute Button N N/A

Owner’s Manual for MDG25IF4 17

Page 22

General Information

GEN

WARNING

Personal injury. Press the emergency stop button to stop the engine immediately in case of an emergency. Failure to do so could result in death or serious injury.

(000298a)

CAUTION

(000246)

Equipment Damage. The emergency stop switch is not to be used to power down the unit under normal operating circumstances. Doing so will result in equipment damage.

Manual Mode

3 PHASE

Volts

Amps

480

128

100

110

Time to Empty

15 hr

Full

3/4

1/2

1/4

Empty

GEN

002787

Controller Features and Functions

These buttons are used to enter the various operator screens from any other screen. The operator screens

consist of four screens: Home ( ), Engine ( ),

Generator ( ), and Voltage Adjust ( ). See

Operator Screens.

Fuel Transfer Pump Switch

Used to allow fuel into the engine.

Engine Speed Switch

Provides engine overspeed protection.

Navigation Buttons

Used to navigate through the various operator screens.

Engine START Button

Press the engine START (I) button while the controller is in MANUAL mode to start the unit. If there are no shutdown errors and the engine satisfies the start status the unit will start. If the controller is in AUTO mode, the engine START (I) button has no effect.

Engine STOP Button

Generator Button

Press to display the Generator Screen.

Engine Button

Press to display the Engine Screen.

Home Button

Press to display the Home Screen.

Controller Power Switch

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

Operator Screens

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

Home Screen

The home screen is the controller’s default screen and automatically displays 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.

Press the engine STOP (O) button to shut down the unit and put the controller into STOP mode, whether in MANUAL mode or AUTO mode.

AUTO or MANUAL Mode Button

Changes the startup and shutdown modes of the unit. The unit enters MANUAL mode when pressed once. The unit enters AUTO mode when pressed and held for five seconds. If in AUTO mode, pressing once will return the unit to MANUAL mode.

Alarm Mute Button

Silences the audible alarm. Additional action will be required to fully disable the active alarm.

Voltage Adjust Button

Press to display the Voltage Adjust Screen.

18 Owner’s Manual for MDG25IF4

Figure 2-7. Home Screen

Engine Screen

The engine screen displays the oil pressure, coolant temperature, and battery voltage on three main gauges. An hour gauge displaying the total run time on the engine is below the gauges. The hour gauge also displays maintenance alarm status at the bottom of the screen, with the time remaining (black text) or the time passed (red text), a scheduled maintenance task, along with the description of the maintenance procedure, and the action that will take place when the timer trips the alarm.

Page 23

General Information

002788

Manual Mode

GEN

Parallel Low Zig-Zag

L1 (U)

L2 (W)

Volt Volt Amp kW

L1-L2 L1

L2-L3 L2

L3-L1 L3

0 0 0

0.0

AmpVolt

Freq

30 40

70 0

175

263

350 0

002789

Manual Mode

40 60

170

190 210

230

20 30

50.9

100

PSI

0 0 3 2 5 1 5

214

250

°F

Hrs

13.8

Shutdown

Electrical Trip

50150

Warning

GEN

Oil press. Coolant Temp. Battery

Maintenance

Alarm Hours Description Action

1 174 To Service Oil Maintenance 2 174 To Service Fuel Maintenance 3 174 To Service Air Maintenance

Figure 2-8. Engine Screen

NOTE: If the measured value is outside the range of a gauge, the needle will not be displayed. The digital value below the gauge will still show the measured value.

• Oil Press: Displays engine oil pressure. Current

coolant temperature displays directly below the gauge at all times. The gauge registers oil pressure between 0–100 psi (0–689 kPa). Normal operating pressure is between 35–80 psi (241–552 kPa).

• Coolant Temp: Displays engine coolant

temperature. Current coolant temperature displays directly below the gauge at all times. The gauge displays coolant temperature between 150–250 °F (66–121 °C). Normal operating temperature of the unit is between 180–200 °F (82–93 °C) with an average ambient air temperature of 70 °F (21 °C).

• Battery: Displays the engine battery voltage.

Current battery voltage displays directly below the gauge at all times. The gauge displays battery voltage between 0–50V. A normal reading is 12– 14V on 12 volt systems and 24–26V on 24 volt systems (with the engine running).

Generator Screen

The generator screen displays the average voltage frequency, volts and amps from the generator, as well as line-to-line voltage, and individual line-to-neutral voltage, amperage, and power (kW). This screen also displays the generator winding configuration set by the voltage selector switch in the lower right corner.

Figure 2-9. Generator Screen

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

• Freq: Displays the output frequency in Hertz (Hz).

Normal operating frequency is 60 Hz.

• Volt s: Displays the nominal voltage in volts (V).

• Amps: Displays the AC output amperage

produced by the generator in amps (A).

Additional information can be found on the electric power table at the bottom-left side of the screen. This provides an overview of all three lines and average voltage and amperage readouts.

Voltage Adjust Screen

The unit automatically fine tunes voltage upon start-up after the output voltage is selected and the unit is started. See Voltage Selector Switch. The voltage can be manually fine tuned as needed. See Fine Voltage

Adjustment.

The voltage adjust screen displays the line-to-neutral and line-to-line voltage averages. The operator can electronically adjust the voltage within limits to prevent under-voltage or over-voltage conditions using the onscreen instructions. This feature replaces a traditional potentiometer.

Owner’s Manual for MDG25IF4 19

Page 24

General Information

Manual Mode

GEN

Voltage Adjust

- Press , voltage will begin flashing

- Use and arrows to adjust voltage

- Press to confirm new voltage. Numbers will stop flashing

L-N Average

L-L Average

277 480

002803

SITE GENSET

07:10

480V/277V 3-Phase

Return Delay 10:00:00

Total

kWh+

kVAh

kVArhpf

kVAr

kVA

0.0

0.00

0.0

kVAr

Energy Generator

002790

GEN

SITE GENSET

7741 \ 7740

07:10

480V/277V 3-Phase

Status

Schedule

I/O

AlarmsEngine Generator

1/9

Engine Starts

Fuel Used

Fuel Remaining

US Gal

Litre

Hrs

RPM

00000 00

Oil press. Coolant Temp.

Charge AltBatteryOil Temp

Fuel Level

°F V

°FPSI

0.0

00.00

20 30

10 -50

50 150

200

250 0

40 60

100

-50

50 150

200

250

100

CAN

12 15

007616

GEN

SITE GENSET 7741 \ 7740

07:10

480V/277V 3-Phase

StatusSchedule

I/O

AlarmsEngine

Generator

1/9

L1-L2

L2-L3

L3-L1

Volt Volt Amp kW kVA kVAr pf

0.0

0 0

0 0 00

0 0 0

L1-L2 L2-L3 L3-L1 Hz

FreqVoltVoltVolt

100

200

300

400

500

600

100

200

300

400

500

600 0

100

200

300

400

500

600 0

30 40

007617

Figure 2-10. Voltage Adjust Screen

Maintenance Screens

All of the data inputs from the engine, generator, inputs/ outputs, schedule, and PowerZone controller are visible on the maintenance screens.

The information displayed on the maintenance screens can be used to identify, diagnose, and troubleshoot unit shutdown conditions and poor unit performance. The maintenance screens can be accessed from any operator screen by pressing any directional arrow (▲, ►, ▼, ◄).

The bottom of the screens have a list of available tabs, with the currently displayed tab highlighted in blue. The tabs can be selected by using the ► or ◄ buttons. The current/available pages are displayed to the left of the tabs. The pages within a tab can be viewed by using the ▲ and ▼ buttons. Whenever a new tab is selected, the current page will always be page one.

Generator Summary

The generator summary can be found at the top of all maintenance screens and provides an overview of the system.

Engine Tab

The engine tab contains maintenance and instrumentation data gathered from the engine. Above the engine analog meters is a row of alarm icons. Each icon can be one of three colors: gray (inactive), yellow (warning), or red (shutdown). The alarm icons from left to right are: water in fuel, emission filter, engine air inlet temperature, charge alternator, oil pressure, fuel level, battery voltage, coolant temperature, and ECU lamp.

NOTE: The content may change depending upon the selected engine and the features supported by the engine.

Figure 2-12. Engine Tab Screen

Generator Tab

The generator tab contains maintenance and instrumentation data gathered from the generator. Each page highlights different data gathered by the generator, with the analogue meters changing accordingly. The last two pages display the information in the bar graph. The bar graph is blue for positive and red for negative. For the power factor bar graph, blue is for lagging pf and red is for leading pf.

NOTE: The content may change depending upon the selected generator and the features supported by the generator.

Figure 2-11. Generator Summary Screen

20 Owner’s Manual for MDG25IF4

Figure 2-13. Generator Tab Screen

Page 25

Alarms Tab

GEN

SITE GENSET 7741 \ 7740

07:10

480V/277V 3-Phase

Return Delay 10:00:00

0.0

Total Generator

kWh+

kVAh

kVArh

kVA

kVAr

0.0

0.00

0.0

% %

0.0

kVAr

StatusSchedule

I/O

AlarmsEngine Generator

1/2

Warning Shutdown Electrical Trip

Engine

002793

GEN

SITE

GENSET

7741 \ 7740

07:10

480V/277V 3-Phase

Return Delay 10:00:00

0.0

Total Generator

kWh+

kVAh

kVArh

kVA

kVAr

0.0

0.00

0.0

% %

0.0

kVAr

Status

Schedule

I/O

AlarmsEngine Generator

2/2

Warning

Shutdown Shutdown

Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown

This is an event index 1 This is an event index 2 This is an event index 3 This is an event index 4 This is an event index 5 This is an event index 6 This is an event index 7 This is an event index 8 This is an event index 9 This is an event index 10 This is an event index 11 This is an event index 12 This is an event index 13

1 01/01/1970 00:00:01 0:00 2 02/06/1970 11:45:55 0:00 3 01/01/1970 00:00:00 0:00 4 01/01/1970 00:00:00 0:00 5 01/01/1970 00:00:00 0:00 6 01/01/1970 00:00:00 0:00 7 01/01/1970 00:00:00 0:00 8 01/01/1970 00:00:00 0:00 9 01/01/1970 00:00:00 0:00 10 01/01/1970 00:00:00 0:00 11 12 01/01/1970 00:00:00 0:00 13 01/01/1970 00:00:00 0:00

01/01/1970 00:00:00 0:00

Index Date Time Hrs Event Details

002794

GEN

SITE GENSET 7741 \ 7740

07:10

480V/277V 3-Phase

Return Delay 10:00:00

0.0

Total

Generator

kWh+

kVAh

kVArh

kVA

kVAr

0.0

0.00

0.0

% %

0.0

kVAr

StatusSchedule

I/O

AlarmsEngine Generator

1/38

Digital Inputs

Ip Description Active State Ip Description Active State

002795

The alarms tab displays warnings, electrical trip, shutdown alarms, and any engine diagnostic trouble codes (DTC) that are occurring or have occurred. The first page displays the alarms that are currently active and organizes them by alarm type.

Figure 2-14. Alarms Tab Screen (Page One)

General Information

Figure 2-15. Alarms Tab Screen (Page Two)

To scroll down within the event log, press the ENTER () button. The scroll bar will activate and change to blue. Press the ▲ or  buttons to scroll up or down in the event log. Press the ENTER () button again when finished.

Table 2-3. Diagnostic Trouble Codes

Alarm

Typ e

Warning Yellow/Black

Electrical

Trip

Shutdown Red/Black

ECU

Code

Color–

Background/Text

Purple/Black

Blue/White

Graphic

Warning

Electrical Trip

Shutdown

Engine

The second page of the alarms tab shows the event log with a list of events, including normal operation events and alarm notifications. The most recent events are listed first. All indexed events include the date and time of the event, and hours of runtime on the engine when it occurred, along with the event name or alarm type and details.

Input/Output Tab

The input/output (I/O) tab shows a list of digital inputs and outputs connected to the controller, whether they are active or not, and the current state (open/closed status) of the input and output.

Figure 2-16. Input/Output Tab Screen

Owner’s Manual for MDG25IF4 21

Page 26

General Information

GEN

SITE GENSET 7741 \ 7740

07:10

480V/277V 3-Phase

Return Delay 10:00:00

0.0

Total Generator

kWh+

kVAh

kVArh

kVA

kVAr

0.0

0.00

0.0

% %

0.0

kVAr

StatusSchedule

I/O

AlarmsEngine Generator

1/1

Warning Warning Warning

ActionDescription

Alarm Hours Date Time

Maintenance

Scheduler Enabled to run Reserved Reserved

Event Week Day Start Stop Duration Event Week Day Start Stop Duration

250 hr Maint. - Refer to Manual

500 hr Maint. - Refer to Manual

3000 hr Maint. - Refer to Manual

1 250:00

2 500:00 3 3000:00

All Monday 00:00 00:00 0:00

All Monday 00:00 00:00 0:00 All Monday 00:00 00:00 0:00 All Monday 00:00 00:00 0:00 All Monday 00:00 00:00 0:00 All Monday 00:00 00:00 0:00

9 10 11 12 13 14 15 16

All Monday 00:00 00:00 0:00 All Monday 00:00 00:00 0:00 All Monday 00:00 00:00 0:00 All Monday 00:00 00:00 0:00 All Monday 00:00 00:00 0:00 All Monday 00:00 00:00 0:00 All Monday 00:00 00:00 0:00 All Monday 00:00 00:00 0:00

1 2 3 4 5 6 7 8

002796

GEN

SITE GENSET 7741 \ 7740

07:10

480V/277V 3-Phase

Return Delay

10:00:00

0.0

Total Generator

kWh+

kVAh

kVArh

kVA

kVAr

0.0

0.00

0.0

% %

0.0

kVAr

StatusSchedule

I/O

AlarmsEngine Generator

1/1

- DCD

- DSR

- DTR

- RTS

- CTS

Model

Link Quality

100%

Application USB ID Supervisor State: Engine State: Load State:

Protections: Logging Log Dest: Log Mode: USB drive: Host IP: Host Port:

Slave IP: Slave Port:

Total mem Log mem free Log Time:

Bootloader Analogue Engine:

Model Application USB ID Bootloader Ethernet

002797

WARNING

Electric Shock. Never change the voltage selector switch while the engine is running or the controller is on. Doing so could result in death, serious injury or equipment damage.

(000302)

Scheduler Tab

The scheduler tab shows the current configuration and status of the scheduler, located below the generator summary. The maintenance configuration status and time remaining until an alarm, electrical trip, or shutdown will be displayed at the bottom of the screen. The lamp(s) to the left shows the configuration status of the maintenance alarm, not the alarm condition.

Figure 2-17. Schedule Tab Screen

Status Tab

Engine Monitoring

Engine information is displayed on both the engine operator screen and engine tab within the Maintenance

Screens. See Engine Tab.

PowerZone Controller Information Displays, Functions, and Reset

The PowerZone controller constantly monitors vital generator and engine functions for a number of operation, alarm, and fault conditions. When a fault condition occurs, the engine shuts down automatically and the main display shows the fault that caused the shutdown. The fault condition must be resolved to resume operation. Press the ENTER () button to reset the controller and resume operation.

Voltage Selector Switch

The status tab contains the status and configuration of the controller, firmware, and data connections.

Figure 2-18. Status Tab Screen

Generator Monitoring

Generator information is displayed on both the generator button screen and generator tab within the Maintenance

Screens. See Generator Tab.

The voltage selector switch mechanically configures the main windings of the generator to provide a Hi Wye, Low Wye, Zig Zag or Delta (if equipped) configuration providing single and three phase voltage output to the main breaker. Voltage ranges are selected by rotating the handle on the switch to the desired voltage.

The voltage selector switch is equipped with a lockout mechanism to prevent unauthorized changing of the voltage setting by locking the handle in place.

See Using the Voltage Selector Switch for instructions on switching the voltage.

22 Owner’s Manual for MDG25IF4

Page 27

Section 3: Operation

(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.

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

(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.

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

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)

82%

Image File Transer...



002804

Operation

Pre-start Checklist

All items in the pre-start checklist must be completed before starting the unit. This checklist applies to both manual and remote starting of the unit.

 Verify all maintenance procedures are up to date. For

more information, see General Maintenance and

Basic Maintenance Schedule.

 Verify the unit is level.  Verify there is no water inside, on, or near the unit;

dry if needed.

 For grounding requirements, follow any local, state,

or National Electrical Code (NEC) guidelines.

 Verify the control power switch is OFF (O).  Verify all circuit breakers are OFF (O).  Inspect all electrical cords; repair or replace any that

are cut, worn, or bare.

 Verify oil, coolant, and fuel levels are correct, per the

engine manufacturer’s manual.

 Verify battery connections are secure.  Turn the battery disconnect switch ON (if equipped).  Verify engine fan belt tension and condition are within

spec.

 Verify engine fan belt guard is installed and secure.  Check engine exhaust system for loose or rusted

components.

 Verify the radiator and surrounding shroud are clear

of debris.

 Verify all covers are in place and secure.

Owner’s Manual for MDG25IF4 23

 Verify all electrical connections at the connection

lugs, if equipped, are tight and wired correctly.

 Verify the voltage selector switch is set to the desired

voltage and locked.

 Verify the emergency stop switch is pulled out.  Verify all doors on the unit are closed.

Manually Starting the Unit

All units equipped with the PowerZone controller will initially start up in STOP mode. Proceed as follows to start the generator in MANUAL mode:

1. Set the control power switch to ON (I).

2. The display screen will show the pre-start diagnosis, and the controller will load the unit management software.

Figure 3-1. Pre-start Screen

3. The home screen will be displayed when the software is loaded, and the controller will be in STOP mode as indicated at the top of the screen.

Press the AUTO or MANUAL mode ( ) button to enter MANUAL mode.

Page 28

Operation

Stop Mode

3 PHASE

Volts

Amps

0.0 kW

100

110

Time to Empty

15 hr

Full

3/4

1/2

1/4

Empty

GEN

002805

the generator, depending on the type of engine governing used.

11. If all wiring connections have been made correctly, switch the main circuit breaker to ON (I), and then add any loads attached to the receptacles by switching the respective circuit breaker to the ON (I) position. A slight change in engine sound when a load is applied to the unit is normal.

AUTO (Remote) Starting the Unit

AUTO mode is used when the unit is started from a location other than the control panel by using a transfer

Figure 3-2. Home Screen

NOTE: The controller can be started from any screen when it is in MANUAL mode.

4. Pressing the green engine START (I) button on the controller will initiate the startup procedure and start the engine, if there are no engine faults preventing the unit from starting.

NOTE: It may take a few seconds for the engine to run smoothly and reach its governed operating speed. During this time, the screen will show a voltage different from the voltage set with the voltage selector switch.

5. If the engine does not start after the first cranking attempt, the engine will pause for 15 seconds to allow the starter to cool. The display screen will show MANUAL MODE - CRANK REST at the top of the screen. The engine will make two more attempts to start for a total of three crank cycles.

6. If the engine does not start and run within three crank cycles, the display screen will show the fail to start alarm. The starting sequence can be repeated after the starter has had a minimum of two minutes to cool. Pressing the ENTER () button will clear the alarm and reset the controller.

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

7. Once the engine starts, it begins speeding up to a constant 1800 RPM. The engine may hunt or change speeds until operating speed is reached. The engine will be warmed up and the operator screens will show engine and generator operating parameters after a few minutes of operation.

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

9. Verify the AC output voltage is correct. See Fine

Voltage Adjustment.

10. Verify the frequency (Hz) is correct on the

24 Owner’s Manual for MDG25IF4

generator screen. The frequency should read approximately 60 Hz with no loads connected to

switch. AUTO (remote start) is the normal setting when the unit is being used as a standby power supply. Review the Pre-start Checklist and Manually Starting the Unit before putting the unit in AUTO mode. Follow all safety warnings and review all information on isolating the generator with a transfer switch if the unit is to be used as a standby power supply. See AUTO Exercise Timer, then proceed as follows:

1. Perform a manual start of the unit at least once to verify the engine is operating correctly.

2. To check the remote start circuit, remove the wires from the remote start terminal block. Press the

AUTO or MANUAL mode ( ) button, and the display screen will show auto mode at the top of the screen.

3. Attach a jumper wire (minimum 16 gauge) across the two terminals on the remote start terminal block. This applies a ground to the PowerZone controller to close the starting circuit contacts. The engine will crank, start, and run.

4. Remove the jumper wire from the remote start terminal block and the engine will stop. Reconnect any necessary wires from the remote start switch (transfer switch) to the remote start terminal block.

5. Verify the unit is in AUTO mode. The display screen should show AUTO mode at the top of the screen.

6. Switch the main circuit breaker ON (I).

7. Secure the unit by closing and locking all access doors.

8. The unit is now ready for remote starting.

See Figure 3-3. The remote start terminal block provides a connection for installation of a remote start switch which will allow the unit to be started by a remote drycontact closure switch. For location of the remote start terminal block, see Figure 2-4.

Before entering AUTO mode, verify the contacts on any remote switch linked to the unit are open. If the contacts on a remote switch are closed, the engine will crank and start when AUTO mode is entered. Attach the switch leads to the two unused terminals (A) on the unit’s remote start terminal block.

Page 29

Figure 3-3. Remote Start Terminal Block

002806

DANGER

Explosion. Do not use ether when starting an engine equipped with glow plugs or an air intake heater. Doing so could cause an explosion, which will result in death or serious injury.

(000583)

008744

Wet Stacking

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

Operation

shore power 120V electrical connection that can be found in the convenience receptacle. The crankcase ventilation heater is powered by the generator and will stay on when the engine is operating in cold weather conditions.

Figure 3-4. Cold Weather Starting Guidelines

A No Aids

B Electric Air Heat

C Block Heat

D Ether

Cold Weather Operation

Use cold weather starting aids as needed according to

Figure 3-4. Follow supplier instructions for starting aids

provided on engine. A booster battery can be connected

if needed (see Using a Booster Battery or Charger (if The engine may be equipped with optional equipment, such as a coolant heater, oil pan heater, crankcase ventilation heater, battery heater or fuel heater as cold weather starting aids.

See Figure 3-4. Starting aids are required below 32°F (0°C). They will enhance starting performance below these temperatures and may be needed to start applications that have high parasitic loads during cranking and start acceleration to idle. Other cold weather starting aids are required at temperatures below

-13°F (-25°C) or at altitudes above 5000 ft (1500 m). The use of correct grade oil (see Recommended Oil

Types) is critical to achieving adequate cold weather

cranking speed. Synthetic oils have improved flow at low temperatures.

The oil pan heater, battery heater and fuel filter heater (if equipped) are activated with a thermostat and will turn on and off as needed. The coolant heater is powered by a

Owner’s Manual for MDG25IF4 25

equipped)).

NOTE: Turn key to ON but do not crank engine until

Engine Preheat Indicator goes off.

NOTE: Additional information on cold weather operation

is available from your local GMP ASD.

E Electric Air Heat and Block Heat

F Ether and Block Heat

Page 30

Operation

(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.

(000138a)

WARNING

(000167a)

CAUTION

Equipment damage. Do not make battery connections in reverse. Doing so will result in equipment damage.

004507

004508

(000237)

DANGER

Electrical backfeed. Use only approved switchgear to isolate generator from the normal power source. Failure to do so will result in death, serious injury, and equipment damage.

(000157)

DANGER

Electrocution. Do not disable or modify the connection box door safety switch. Doing so will result in death or serious injury.

Using a Booster Battery or Charger (if equipped)

See Figure 3-6. A 12 volt booster battery can be connected in parallel with battery(ies) on the unit to aid in cold weather starting. ALWAYS use heavy-duty jumper cables.

Series:

• Amps = Same as single battery

• Volts = Twice as a single battery

Parallel:

• Amps = Twice as a single battery

• Volts = Same as single battery

Figure 3-6. Parallel

1. Connect booster battery or batteries to produce the required system voltage.

NOTE: To avoid sparks, do not allow the free ends of jumper cables to touch engine.

2. Connect one end of jumper cable to the POSITIVE (+) post of the booster battery.

3. Connect the other end of the jumper cable to the POSITIVE (+) post of battery connected to starter.

4. Connect one end of the other jumper cable to the NEGATIVE (-) post of the booster battery.

5. Complete the hookup by making the last connection of the NEGATIVE (-) cable to a good ground on the engine frame and away from the battery(ies).

6. Start the engine. Disconnect jumper cables immediately after engine starts. Always disconnect NEGATIVE (-) cable first.

Generator Output Connections

Figure 3-5. Series

26 Owner’s Manual for MDG25IF4

Page 31

The installation should be in compliance with the national

(000156)

DANGER

Electrocution. Before connections are made to the unit, verify the main circuit breaker and battery disconnect switch are OFF. Failure to do so will result in death or serious injury.

(000155a)

WARNING

Electric shock. Only a trained and licensed electrician should perform wiring and connections to unit. Failure to follow proper installation requirements could result in death, serious injury, and equipment or property damage.

007618

(000156)

DANGER

Electrocution. Before connections are made to the unit, verify the main circuit breaker and battery disconnect switch are OFF. Failure to do so will result in death or serious injury.

(000237)

DANGER

Electrical backfeed. Use only approved switchgear to isolate generator from the normal power source. Failure to do so will result in death, serious injury, and equipment damage.

WARNING

Electric Shock. Verify all connections to the cam lock receptacles are made to one side only. Failure to do so could result in death, serious injury and property damage.

(000308)

(000155a)

WARNING

L1 L2

N (Neutral)

G (Ground)

Black Red

Blue White Green

007619

electrical code (NEC), state, and local regulations.

See Figure 3-7. The unit is equipped with connection lugs (A), located on the lower portion of the control box behind the lug box door. The lugs provide connection points to attach external loads to the generator. A large decal on the inside of the connection lug door details the proper connections for selected voltages.

Connections to the lugs should be made by running the power cables up through the opening in the bottom of the box.

Operation

Generator Cam Lock Connections (If Equipped)

IMPORTANT NOTE: Do not make any connections directly to the lugs without routing the cables through the opening. Use a hex-wrench to tighten the cable connections.

The connection lug door is equipped with safety interlock switches that will trip the main circuit breaker and disable the voltage regulator if the door is opened while the unit is operating.

A ground connection (B) is located next to the connection lugs. The unit must be connected to ground for proper operating safety. The generator neutral is bonded to ground when it is shipped from the factory. The bonding plate must be removed when the generator is used as a standby power source.

See Figure 3-8. The unit may be equipped with cam lock connections (A) located below the receptacles. These receptacles provide connection points to attach external loads to the generator. A decal below the cam lock connections details the proper connections for selected voltages.

Connections should be made by plugging power cables equipped with series 16 taper nose 400A/600V cam lock plugs into the cam lock receptacles. Secure the connection by rotating the plug a 1/2 turn to the right.

Figure 3-7. Generator Connection Lugs

Owner’s Manual for MDG25IF4 27

Figure 3-8. Cam Lock Connections

Page 32

Operation

(000157)

DANGER

Electrocution. Do not disable or modify the connection box door safety switch. Doing so will result in death or serious injury.

WARNING

Electric Shock. Never change the voltage selector switch while the engine is running or the controller is on. Doing so could result in death, serious injury or equipment damage.

(000302)

Manual Mode

GEN

Voltage Adjust

- Press , voltage will begin flashing

- Use and arrows to adjust voltage

- Press to confirm new voltage. Numbers will stop flashing

L-N Average

L-L Average

277 480

002803

WARNING

Electric Shock. Never change the voltage selector switch while the engine is running or the controller is on. Doing so could result in death, serious injury or equipment damage.

(000302)

CAUTION

(000303)

Equipment Damage. Verify voltage application before making changes to factory settings. Incorrect voltage applied to a load could result in equipment damage.

A ground connection is located on the far right of the cam lock panel. The unit must be connected to a good earthen ground for proper operating safety. The generator neutral is bonded to ground when it is shipped from the factory. The bonding plate must be removed when the generator is used as a standby power source. Installation should be in compliance with the National Electrical Code (NEC), state, and local regulations.

Using the Voltage Selector Switch

2. Press . The voltages displayed will flash.

3. Use ▲ and ▼ to adjust the voltage.

4. Press  to confirm the new voltage. The voltages displayed will stop flashing.

Voltage Regulator

The automatic voltage regulator controls the output of the generator by regulating the current into the exciter field. The voltage regulator is adjusted before shipment from the factory. The regulator has four screwdriver adjustable potentiometers that may be adjusted for under frequency roll-off (U/F), U/F dip (DIP), stability (STAB), and voltage (VOLT). Contact a GMP ASD for additional information before attempting to adjust the voltage regulator.

NOTE: For units equipped with a Marathon DVR2000E+ automatic voltage regulator, see the Marathon operating manual provided with the unit.

Achieving 240V Three-Phase in

1. Shut down the unit according to Shutting Down

the Unit.

2. Remove padlock from voltage selector switch lockout device.

3. Move voltage selector switch to desired voltage.

4. Replace and lock padlock on voltage selector switch lockout device.

5. Start the unit according to Manually Starting the

Unit or AUTO (Remote) Starting the Unit.

Fine Voltage Adjustment

See Voltage Adjust Screen for information on screen display.

1. With the unit running, press .

28 Owner’s Manual for MDG25IF4

Figure 3-9. Voltage Adjust Screen

208V Three-Phase (Parallel Low Wye) Configuration

IMPORTANT NOTE: Using this method to achieve 240V 3Φ will result in a line to neutral voltage of 139V, and is not recommended for single phase usage.

Proceed as follows to check which version of the PowerZone controller application the unit has:

1. With the unit shut down, set the control power switch to the ON (I) position. The controller will toggle automatically to the home screen after initialization.

2. Press ▲, ►, ▼, or ◄ to enter the maintenance screens.

3. Press ► until the status tab is selected. This tab will display which version of the PowerZone application the unit has.

NOTE: The version is also displayed in the top left corner of the Configuration menu. See Accessing the

Configuration Menu.

Page 33

Operation

CAUTION

(000303)

Equipment Damage. Verify voltage application before making changes to factory settings. Incorrect voltage applied to a load could result in equipment damage.

After verifying the unit has V4 or higher of the PowerZone controller application, proceed as follows to achieve 240V while in the 208V configuration:

4. Starting in any of the operator screens, press ▲, ►, ▼, or ◄ to enter the maintenance screens.

5. Press  and O simultaneously. The next screen will display the configuration menu.

6. Press ▼ to move the cursor (blue highlighted text) down to Config Selection.

7. Press ► to highlight Config to Edit. Press ► again to highlight Selected Configuration. Then press  to access the selections.

8. Press ▲ to highlight Alternative Configuration 1. Press .

9. Press ◄ two times to get back to the far left column.

10. Press ▼ to highlight Password Entry. Press  to display the Pin Entry screen. Press  again to access to password entry. The left most pound sign should change to 0.

11. Press ▲, ►, ▼, or ◄ to enter the password 4444 if applicable. Press .

12. Press ▼ to highlight Generator. Press ► again to access the selections.

13. Press ▼ to highlight Generator Voltage. Press ► again to access the selections.

14. Press ▼ to highlight Over Voltage Alarms. Press ► again to access the selections.

15. Press ▼ to highlight Alarm Trip and press  to adjust the voltage.

NOTE: Alarm trip setting must be changed first in order to set the pre-alarm trip setting.

16. Press ▲ until the voltage becomes 153V. Press .

17. Press ▲ and  to adjust the voltage for the Prealarm Trip.

18. Press ▲ until the voltage becomes 151V. Press 

NOTE: It is recommended the current trip settings are also changed. The current values will depend on the unit.

19. Press ▲ and hold  for five seconds until the saving screen appears. The screen will then return to the maintenance screens.

NOTE: Change the alarm settings back for the 208V configuration according to Changing Back to 208V

Configuration.

Changing Back to 208V Configuration

When finished with the 240V settings, change the alarm settings back to the 208V configuration. Follow steps in

Achieving 240V Three-Phase in 208V Three-Phase (Parallel Low Wye) Configuration, changing the pre-

alarm trip to 132V and the alarm trip to 134V.

NOTE: Verify the pre-alarm trip setting is adjusted before the alarm trip setting in order to set the alarm trip setting.

Customer Convenience Receptacles

See Figure 2-4. The unit is equipped with four receptacles. The 240/120V twist-lock receptacles are rated at 50A each. The 120V GFCI receptacles are rated at 20A each, with ground fault circuit interrupt (GFCI) protection. The receptacles are not routed through the main circuit breaker. Each receptacle has its own circuit breaker, located directly above or next to the receptacle. Each breaker is sized to the maximum rating of the corresponding receptacle.

NOTE: Power to the receptacles is available any time the generator is running, even if the main circuit breaker is OFF (O). Verify equipment connected to the receptacles is turned OFF before turning the breakers ON (I).

NOTE: When the voltage selector switch is in position for 480/277V three-phase, voltage at the two GFCI receptacles is 139 volts and the voltage at the three twistlock receptacles is 240/139 volts. Generac Mobile Products LLC does not recommend using the receptacles in the 480V position. When the voltage selector switch is in position for 208/120V three-phase, voltage at the two twist-lock receptacles and the two GFCI receptacles is 208/120 volts.

Main Circuit Breaker

The main circuit breaker is located on the main control panel. See Figure 2-4. When the breaker is OFF (O), power is interrupted to the connection lugs, the optional cam lock receptacles, and the generator. The breaker may be switched ON (I) once the connections have been made to the connection lugs or the optional cam lock receptacles, and the unit has been started and allowed to reach normal operating temperature.

Reasons the main circuit breaker may trip:

• Overload of the generator circuits to the connection

lugs or the optional cam lock receptacles.

• The door covering the connection lugs or the

optional cam lock receptacles is opened.

• If the emergency stop switch is activated.

Verify any problems that cause the main circuit breaker to trip are corrected before returning the switch to ON (I).

Owner’s Manual for MDG25IF4 29

Page 34

Operation

(000190)

DANGER

Loss of life. Property damage. Installation must always comply with applicable codes, standards, laws and regulations. Failure to do so will result in death or serious injury.

(000237)

DANGER

Electrical backfeed. Use only approved switchgear to isolate generator from the normal power source. Failure to do so will result in death, serious injury, and equipment damage.

(000155a)

WARNING

(000226b)

Electric shock. Phase rotation must be compatible. Incompatible phase rotation could result in death, serious injury, or equipment damage.

WARNING

002807

NOTE: The main circuit breaker only interrupts power to the connection lugs and the optional cam lock receptacles. The customer convenience receptacles have power even if the main circuit breaker is OFF (O). Use the individual circuit breakers located near each receptacle to disconnect power to these receptacles.

Transfer Switch

transfer switch automatically returns the load back to the normal source when power is restored back to operating levels.

Figure 3-10. Transfer Switch Operation

A Incoming utility power

Emergency distribution panel (generator power)

C Main distribution panel (utility power)

D Transfer switch

E Power from generator

F Utility meter

WHITE Incoming utility power

GRAY Normal utility power circuit

BLACK Emergency generator power circuit

AUTO Exercise Timer

The installation should be in compliance with the National Electrical Code (NEC), state, and local regulations.

Before any connections are attempted, verify the main circuit breaker and the control power switch are in the OFF (O) position and that the negative (-) battery cable has been disconnected from the battery.

Installation of such devices must be performed by following all directions supplied by the manufacturer of the switch. If attaching the unit to a power supply normally serviced by a utility company, notify the utility company and check state and local regulations. Familiarize yourself with all instructions and warning labels supplied with the switch.

When the unit is used as a standby power supply, it must be equipped with a transfer switch that isolates it from the utility’s distribution system. A transfer switch is designed to transfer electrical loads from the normal power source (utility) to the emergency power source (generator) when normal voltage falls below a prescribed level. The

30 Owner’s Manual for MDG25IF4

The PowerZone controller is capable of starting and stopping the unit automatically, based on a programmable schedule.

Units installed in a standby application should be exercised regularly to maintain operating condition and to ensure responsiveness in an emergency situation. Proceed as follows to operate the unit in AUTO mode:

Accessing the Configuration Menu

1. With the unit stopped, press ▲, ►, ▼, or ◄ to navigate to the maintenance screens from any of the operator screens.

2. While on any maintenance screen, press  and O simultaneously. The controller will display the Configuration menu.

3. To save any changes and exit the Configuration menu, press and hold  for five seconds. To cancel any changes and return to the maintenance screen, press and hold O for five seconds.

Page 35

Operation

Set the Controller Clock

The schedule runs based on the time set in the controller clock. Proceed as follows to set the controller clock before setting the schedule:

1. Navigate to the maintenance group and press ► to access it.

2. Press ► to select the time section.

3. Set the time and date to the correct local time.

Set the Schedule

NOTE: The controller must be in AUTO mode to run at

the programmed time. Use a trickle or solar battery charger to prevent the controller from draining the battery while in AUTO mode.

1. Access the scheduler group by pressing the ► button.

NOTE: The scheduler group consists of the scheduler options and scheduler setup sections. Each section can be accessed and exited using the ► and ◄ buttons.

2. Access the scheduler options section. Within this section, the scheduler can be enabled, run mode selected, and load mode selected.

Table 3-1. Scheduler Options

Item Values

Enable Yes, No

Run Mode Monthly, Weekly

Load Idle, In Island, On Load, Off Load

3. Access the scheduler setup section. In this section, each schedule entry can be modified by pressing the  button to select the item, and the ▲ and ▼ buttons to define them.

Table 3-2. Scheduler Setup

Item Values

Schedule Entry 1-16

Start Time 00:00-23:59

Duration 00:00-99:59

Day Monday-Sunday

Setting Up a Daily Scheduled Run

1. Enable the scheduler.

2. Set RUN mode to Weekly.

3. Set load to preferred method.

4. Set the start time and duration for seven days (Monday–Sunday).

5. Set the controller to AUTO mode.

Set the Unit to AUTO Mode

From any operator or maintenance screen, press and hold the AUTO or MANUAL mode ( ) button for five

seconds, or until AUTO mode is displayed at the top of the screen.

NOTE: If any of the scheduled time slots are currently active, the controller will begin the starting sequence and start the unit, provided there are no shutdown conditions present.

Shutting Down the Unit

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

1. Remove all loads from the generator by opening all circuit breakers (turn OFF (O)).

2. Allow engine to run for approximately five minutes to allow it to cool down.

3. Press the red engine STOP (O) button on the controller. This will result in the generator going into the shutdown cycle and starting a 15 second shutdown timer. If the unit does not shut down within 15 seconds, a stop fail alarm will be displayed on the display screen.

4. After the unit shuts down, wait two minutes after engine shutdown for controller actuated actions to complete and then set the control power switch to OFF (O).

NOTE: Turning off the control panel before the controller finishes updating could cause a loss of data.

NOTE: For extended storage time, disconnect the battery. See the engine operator’s manual for extended storage requirements.

Week (of month) First, Second, Third, Fourth

NOTE: If setting up a daily scheduled run, select Weekly Run Mode, then set start time and duration for each day (seven schedule entries total). This will repeat the seven day schedule as long as the unit is in AUTO mode.

Owner’s Manual for MDG25IF4 31

Page 36

Operation

CAUTION

(000246)

Equipment Damage. The emergency stop switch is not to be used to power down the unit under normal operating circumstances. Doing so will result in equipment damage.

CAUTION

(000305)

Equipment Damage. Do not start the engine with the Engine Control Unit (ECU) override switch ON. Doing so will damage the ECU.

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.

Emergency Stop Switch

See Figure 2-3. The unit is equipped with one emergency stop switch. The red button is clearly labeled EMERGENCY STOP. The switch can be accessed and activated with all doors closed and locked.

Activate the emergency stop switch by pushing the button in until it locks down. This trips the main circuit breaker which then opens the contact, disconnecting the load to the connection lugs. This will also open the fuel circuit, shutting down the engine. The emergency stop fault will be displayed on the control panel. The switch will remain closed until it is pulled out.

Idle Switch

The idle speed is 1,000 to 1,200 rpm. The engine will start at idle speed and run at idle for 15 seconds no matter what position the idle switch is in. After 15 seconds of running at idle, the unit will ramp up to 1,800 rpm if the idle switch is OFF. Otherwise the unit will continue to idle if the idle switch is ON.

When the engine is at idle speed (1,000 RPM), the voltage regulator will not function and the output voltage is dropped out by the voltage regulator.

IMPORTANT NOTE: Do not apply load to the unit when the engine is running at idle speed.

Using the ECU Override Switch

IMPORTANT NOTE: Starting the engine with the ECU override switch ON will not allow the engine to shut down properly using the Engine STOP Button. This must only be used when the engine is OFF.

Towing the Unit

1. Verify the engine is OFF.

2. Use the tongue jack to raise or lower the trailer onto the hitch of the towing vehicle. Lock the hitch coupling and attach the safety chains or cables to the vehicle. Release the jack locking pin and rotate the jack into the travel position. Verify the locking pin snaps into place.

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

3. Lubricate the grease fittings located on the leveling jacks to verify proper operation of the jacks. See

Jack Maintenance. For maintenance interval

information, see Basic Maintenance Schedule.

4. Connect trailer wiring to the tow vehicle. Check for proper operation of the directional and brake lights.

5. Verify all doors and hoods are properly latched.

6. Check for proper inflation of the trailer tires. Proper inflation is specified in Specifications.

7. Check the wheel lugs. Tighten or replace any lugs that are loose or missing. If a tire has been removed for axle service or replaced, tighten the lugs in the order shown in Figure 3-11 to the following specifications:

See PowerZone® Controller for location of the ECU override switch. This toggle switch powers up the ECU without having to start the engine. Use the ECU override switch to turn the ECU OFF. If the unit needs to be shut down immediately, use the emergency stop switch. See

Emergency Stop Switch.

32 Owner’s Manual for MDG25IF4

a. Start all lug nuts by hand.

b. First pass tighten to 20–25 ft-lbs (27–33 Nm).

c. Second pass tighten to 50–60 ft-lbs (67–81 Nm).

d. Third pass tighten to 90–120 ft-lbs (122–162 Nm).

Page 37

Figure 3-11. Lug Sequence

007620

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

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)

007621

007622

NOTE: Maximum recommended speed for highway towing is 45 mph (72 km/h). Recommended off-road towing speed is 10 mph (16 km/h).

Operation

3. See Figure 3-12 for location of the central lift point

(A) and forklift pockets (B).

4. Attach any slings, chains or hooks directly to the

central lift point.

Figure 3-12. Lifting Points

Tying Down the Unit

When securing the unit for transportation, verify the equipment being used to fasten the unit is in good condition and has sufficient strength to hold the unit in place during transport.

See Figure 3-13. Use the tie-down points (A) as shown.

Lifting the Unit

1. Verify the equipment being used to lift the unit is in good condition and has sufficient capacity. For approximate weights, see Specifications.

2. Close and lock all hoods and doors.

IMPORTANT NOTE: Always remain aware of people and objects around the work site when moving or lifting the unit.

Owner’s Manual for MDG25IF4 33

Figure 3-13. Tie-Down Points

Page 38

Operation

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34 Owner’s Manual for MDG25IF4

Page 39

Section 4: Maintenance

CAUTION

(000306)

Equipment Damage. Failure to perform a daily inspection could result in damage to the unit.

Maintenance

Emissions Information

For emissions information, see the OEM diesel engine manual.

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.

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.

Inspect the fan belt for signs of cracking, fraying, and stretching, and verify the belt is properly seated in the pulley grooves. Replace the belt according to the manufacturer’s recommendations.

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

Belt Tensioners

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

General Maintenance

Poorly maintained equipment can become a safety hazard. Periodic maintenance and occasional repairs are necessary in order for the equipment to operate safely and properly over a long period of time. Never perform any routine service (oil and oil filter changes, cleaning, etc.) unless all electrical components are shut off. Before servicing the unit, always follow the instructions listed below.

• Verify the control power switch is turned OFF (O).

• Verify the circuit breakers are turned OFF (O).

• Activate (push in) the emergency stop switch.

• Disconnect the negative (-) terminal on the battery.

• Attach a DO NOT USE sign to the control panel.

This signifies that the unit is being serviced and reduces the chance of someone inadvertently trying to start the unit.

• Do not wash the unit with a high pressure hose or

with any kind of power washer.

• Do not wash the engine block or fuel tank with a

power washer or steam cleaner. Water may enter the cabinet and collect in the generator windings or other electrical parts, causing damage.

• Inspect for water inside the cabinet and generator

before each use if the unit is stored outside. If wet, dry the unit thoroughly before starting.

• Inspect condition of electrical cords. DO NOT use

the unit if insulation is cut or worn through.

• Verify the condition of the air filter by viewing the

level of the vacuum draw on the filter minder gauge. Replace the air filter when the yellow center bar reaches the red section on the gauge (20 in. H

O).

• Inspect wheel lugs. See Towing the Unit.

• Inspect wheel bearings. See Trailer Wheel

Bearings.

• Inspect the wheel bearings for unusual wear.

• Inspect coolant level daily. See the engine

operator’s manual for coolant recommendations and proper mixture.

– Visually inspect the level in the coolant overflow

tank located near the radiator.

– Normal operating level is between the FULL and

ADD markings on the overflow jug.

– When engine is stopped and completely cool,

coolant may be added directly to the coolant overflow container.

Owner’s Manual for MDG25IF4 35

Page 40

Maintenance

(000149)

DANGER

Risk of poisoning. Do not use mouth to siphon coolant. Doing so will result in death or serious injury.

(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.

• Check the oil level daily. See the engine operator’s

manual for the proper viscosity grade of oil, including special operating conditions such as a change in season or climate.

– DO NOT start the unit if the engine oil level is

below the add mark on the dipstick.

– Normal operating level is in the cross-hatch

pattern between the FULL and ADD markings on the dipstick.

– Add oil only if the oil level is below the ADD mark

on the bottom of the cross-hatch pattern on the dipstick.

– DO NOT OVERFILL the crankcase.

• Verify the fuel level.

• Verify the remote switch is also off and tagged if

the unit is connected to a remote start or transfer switch.

NOTE: If the engine was run out of fuel, or the fuel tank was drained, it may be necessary to purge the fuel lines. See the engine operator’s manual supplied with the unit for more information.

Engine Oil Recommendations

The engine oil should be serviced in accordance with the recommendations of this manual to maintain the product warranty.

The engine has been filled with factory engine oil of a grade recommended by the engine supplier.

Use a high quality detergent oil with an appropriate classification and viscosity for the engine type and ambient temperature conditions. Contact a GMP ASD or refer to the applicable engine service manual for more information.

Recommended Oil Types

•

Besco Super: CC

• Besco S – 3: CD

• Besco Multi Z: CD

Coolant Recommendation

Contact a GMP ASD or refer to the applicable engine service manual for engine coolant recommendations.

See table below for mixtures:

Freezing Point °F (°C)

Water (% Volume) 50 40 40 40

Anitfreeze (% Volume) 50 60 60 60*

* Maximum freeze protection is at 60%.

-12

(-24)

-34

(-36)

-54

(-48)

-90

(-67)

Basic Maintenance Schedule

See the original equipment manufacturer’s operating manual for a complete list of maintenance requirements. Failure to comply with the procedures as described in the engine operator’s manual will nullify the warranty, decrease performance, and cause equipment damage or premature equipment failure. Maintenance records may be required to complete a warranty request.

IMPORTANT NOTE: Refer to the engine operator’s manual for additional maintenance information.

36 Owner’s Manual for MDG25IF4

Page 41

Maintenance

Table 4-1. Basic Maintenance Schedule

First 50

Item Daily

Hrs.

(Break-

Every

250

Hrs.

Every

500 Hrs.

Every

2000

Hrs.

Require

Period)

Check engine oil level ♦ Check engine coolant level ♦ Check fuel level ♦ Drain fuel filter ♦ Check tire pressure ♦ Check all electrical connections ♦ Clean battery ♦ Check fan belt tension (replace if necessary) ♦ Inspect radiator fins for debris; clean as

required

♦

Pre-heating condition check ♦ Check engine starting and noise conditions ♦ Check exhaust smoke condition ♦ Perform Daily Walk Around Inspection ♦

Replace engine oil ♦

Replace fuel filter elements

Clean water sedimenter element

Electromagnetic pump filter replacement or cleaning

♦

Oil filter element replacement ♦♦ Replace air filter element ♦ Lubricate leveling jacks ♦

Checking Generator Drive Plate Torque ♦

Replace fan belt ♦ Service air cleaner filter elements ♦

* If the unit is operated in a harsh environment or fuel quality is questioned, replace every 250 hours instead of every 500 hours.

Engine Break-In Requirements

NOTE: During the first 20 hours of operation, avoid long

periods of no load or sustained maximum load operation. If the generator is to run for longer than five minutes without a load, shut down the generator.

Operate the engine at heavy loads (60–90% of maximum) as much as possible. If the engine has spent significant time at idle, constant speed(s), or light load, or if makeup oil is required, a longer break in period may be needed. Refer to the engine operator’s manual for a full description of necessary procedures on the addition of break-in oil and extension of the break-in period. For more information on regular maintenance intervals, refer to Basic Maintenance Schedule.

Owner’s Manual for MDG25IF4 37

Resetting Maintenance Alarms

The PowerZone controller will display a warning message when the unit is due for maintenance or service. The maintenance or service interval is set at 250, 500 and 3,000 hours of engine running time. Once the unit has been serviced, the appropriate maintenance alarm reminder must be reset. Proceed as follows to reset the maintenance alarms:

1. With the unit shut down, move the control power switch to CONTROL ON (I). The controller will toggle automatically to the home screen after initialization.

2. Press ▲, ►, ▼, or ◄ to enter the maintenance screens.

Page 42

Maintenance

Oil

Grease

Oil

Grease

002823a

Grease

Oil

002824a

Oil

002825a

3. Press  and O simultaneously. The next screen

displays the Configuration menu.

4. Press  to move the cursor (blue highlighted text) down to the maintenance group.

5. Press ► to access the sections. Press  to highlight the maintenance section.

6. Press ► to access the parameters and highlight the maintenance alarm that needs to be reset.

7. Press  to select the editable parameters. The cursor will highlight NOT RESET under the selected maintenance alarm. Press  to highlight RESET.

8. Press  to reset the selected maintenance alarm.

9. To perform additional maintenance alarm resets,

repeat steps 6–8.

NOTE: If the selected maintenance alarm does not need to be reset, press  to highlight Not Reset and press  to return to the parameters section.

10. Press and hold  for five seconds to save changes. Press and hold O for five seconds to discard changes made.

Top-Wind Models

•

Apply a lightweight oil to the screw stem.

Checking Generator Drive Plate Torque

1. Disconnect battery.

2. Remove generator fan guard.

3. Tighten each of the drive plate bolts to

30 ft-lbs (40 Nm).

4. Install generator fan guard.

5. Connect battery.

Jack Maintenance

The following procedures should be performed annually.

Side-Wind Models

•

The internal gearing and bushings of the jack must be kept lubricated. Apply a small amount of automotive grease to the internal gearing by removing the jack cover, or if equipped, use a needle nose applicator or standard grease gun on the lubrication point on the side of the jack near the crank. Rotate the jack handle to distribute the grease evenly.

• A lightweight oil must be applied to the handle unit

at both sides of the tube.

• If equipped, the axle bolt and nut assembly of the

caster wheel must also be lubricated with the same lightweight oil.

Figure 4-1. Lubrication Points

Trailer Wheel Bearings

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

38 Owner’s Manual for MDG25IF4

Page 43

Troubleshooting

Section 5: Troubleshooting

General Troubleshooting

This information is intended to be a check or verification for simple causes that can be located and fixed. It does not cover all types of problems. See the engine operator’s manual for additional troubleshooting information. Procedures that require in-depth knowledge or skills should be performed by a GMP ASD.

Problem

Low Fuel Level Shutdown

Low Oil Pressure Shutdown

Low Coolant Level Shutdown

Possible Cause Solution

Low fuel level

Unit not level

Fuel tank leaking

Damaged fuel sender or wiring

Low oil level

Oil leaking from engine

Oil pressure sender

Low coolant level

Coolant hoses leaking

Engine block or water pump leaking

Check fuel level in LCD window of controller.

Confirm that unit is sitting level to ensure an accurate reading.

Check tank for leaks.

Check for continuity between sender and engine controller. (See

DC Wiring.)

Check oil level on dipstick. Add oil, if needed.

Visually inspect the engine for leaks. Restart unit and verify loss of pressure. Shut down immediately if pressure does not reach 5 psi (34 kPa) within five seconds.

See engine operator’s manual to identify corrective action.

Allow engine to cool, then check coolant level in radiator. Add coolant, if needed.

Inspect hoses for leaks. Repair or replace as necessary.

Visually inspect for leaks. Verify no coolant has mixed with the engine oil (oil will appear milky). See engine operator’s manual for additional information.

Low coolant level

High Coolant Temperature Shutdown

Overcrank Shutdown Fuel level low

Overspeed or Underspeed Shutdown

Blockage in radiator

Leakage in coolant hoses, engine block, or water pump

Frequency setting incorrect

Add coolant if needed. Allow engine to cool, then check coolant level in radiator. Restart engine and check coolant temperature (on controller). Stop engine immediately if coolant temperature is 210°F (99°C) or more.

Check radiator shroud and ducting for blockage and remove any foreign matter.

Inspect for visible leaks. Check tension of water pump serpentine drive belt. Remove load on generator and restart engine. Check coolant temperature and shut engine down immediately if it starts to overheat (230 degrees or higher). See the engine operator’s manual for additional information on engine overheating.

Check fuel level in tank. Check fuel pump operation. Check air filter for blockage. See engine operator’s manual for additional information.

Disconnect all loads and restart unit. Read frequency (Hz) in the LCD window on controller. Frequency should read 60 Hz. If frequency is above 60 Hz, engine speed will need to be adjusted. Contact Isuzu to adjust speed.

Owner’s Manual for MDG25IF4 39

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Troubleshooting

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40 Owner’s Manual for MDG25IF4

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Wiring Diagrams and Service Log

Section 6: Wiring Diagrams and Service Log

Wiring Diagram - 3 Position AC Box

Owner’s Manual for MDG25IF4 41

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Wiring Diagrams and Service Log

Wiring Diagram - 4 Position AC Box

42 Owner’s Manual for MDG25IF4

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Wiring Diagram - Receptacles

Wiring Diagrams and Service Log

Wiring Diagram - Engine Heater

Owner’s Manual for MDG25IF4 43

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Wiring Diagrams and Service Log

Wiring Diagram - Wiring Buck (If Equipped)

Wiring Diagram - Power Zone PMG

44 Owner’s Manual for MDG25IF4

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Wiring Diagram - Power Zone Control Box

Wiring Diagrams and Service Log

Owner’s Manual for MDG25IF4 45

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Wiring Diagrams and Service Log

Wiring Diagram - Trailer Lights

46 Owner’s Manual for MDG25IF4

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Wiring Diagram - Brake Wiring

Wiring Diagrams and Service Log

Owner’s Manual for MDG25IF4 47

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Wiring Diagrams and Service Log

Wiring Diagram - 12V Battery Charger

Wiring Diagram - Power Zone Low Oil Level (If Equipped)

48 Owner’s Manual for MDG25IF4

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Wiring Diagrams and Service Log

OIL GRADE: _____________________________________ BRAND: __________________________________

COOLANT MIXTURE: _____________________________ BRAND: __________________________________

__________________________________________________________________________________________

Date

Hours to

Service

Oil Level

Coolant

Level

Date

Hours to

Service

Oil Level

Coolant

Level

Service Log

Owner’s Manual for MDG25IF4 49

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Wiring Diagrams and Service Log

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50 Owner’s Manual for MDG25IF4

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Part No. 10000024701 Rev. A 06/07/2018 ©2018 Generac Mobile Products, LLC All rights reserved. Specifications are subject to change without notice. No reproduction allowed in any form without prior written consent from Generac Mobile Products, LLC.

Generac Mobile Products, LLC

215 Power Drive, Berlin, WI 54923

GeneracMobileProducts.com │800-926-9768 │920-361-4442

Generac Power Systems MDG25IF4 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Section 1: Introduction and Safety

Introduction

Read This Manual Thoroughly

Safety Rules

Safety Symbols and Meanings

How to Obtain Service

General Hazards

Trailer Hazards

Electrical Hazards Lifting Hazards

Explosion and Fire Hazards

Battery Hazards

Fuel Hazards

Engine Safety

Operating Safety

Positioning the Unit

Towing Safety

Hitch and Coupling

Safe Towing Techniques

Reporting Trailer Safety Defects

Safety and Operating Decals

Section 2: General Information

Specifications

Unit Dimensions

Component Locations

Control Panel

Unit and Serial Number Locations

Altitude and Temperature Limitations

PowerZone® Controller

Controller Features and Functions

Operator Screens

Maintenance Screens

Generator Summary

Engine Tab

Generator Tab

Alarms Tab

Input/Output Tab

Scheduler Tab

Status Tab

Engine Monitoring

PowerZone Controller Information Displays, Functions, and Reset

Voltage Selector Switch

Generator Monitoring

Section 3: Operation

Pre-start Checklist

Manually Starting the Unit

AUTO (Remote) Starting the Unit

Wet Stacking

Cold Weather Operation

Using a Booster Battery or Charger (if equipped)

Generator Output Connections

Generator Cam Lock Connections (If Equipped)

Using the Voltage Selector Switch

Voltage Regulator

Fine Voltage Adjustment

Changing Back to 208V Configuration

Customer Convenience Receptacles

Main Circuit Breaker

Transfer Switch

AUTO Exercise Timer

Accessing the Configuration Menu

Set the Controller Clock

Set the Schedule

Setting Up a Daily Scheduled Run

Set the Unit to AUTO Mode

Shutting Down the Unit

Emergency Stop Switch

Idle Switch

Using the ECU Override Switch

Towing the Unit

Lifting the Unit

Section 4: Maintenance

Maintenance

Emissions Information

Daily Walk Around Inspection

Belt Tensioners

General Maintenance