mdg25if4_diesel-generator_owners-manual.pdf

SAVE THIS MANUAL FOR FUTURE REFERENCE

For technical assistance contact:

www.generacmobileproducts.com Technical Support 1-800-926-9768

Owner’s Manual Diesel Generator

MDG25IF4

SN 3006519573 and higher

Use this page to record important information about your unit.

Record the information found on your unit data label on this page. See unit serial number location (Unit Serial Number Locations). The label plate is affixed to the inside partition, to the left of the control panel console.

Engine and generator serial numbers are located on separate data plates affixed to the engine and generator.

When contacting a Generac Mobile Authorized Service Dealer (GMASD) about parts and service, supply the complete model number and serial number of the unit.

Operation and Maintenance: Proper maintenance and care of the unit 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 GMASD. Normal maintenance, service and replacement of parts are the responsibility of the owner or 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 Model No.

Unit Serial No.

Engine Model No.

Engine Serial No.

Generator Model No.

Generator Serial No.

(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.

Table of Contents

Section 1: Introduction and Safety

Introduction Read This Manual Thoroughly

How to Obtain Service

Safety Rules

Safety Symbols and Meanings

General Hazards

Electrical Hazards

Battery Hazards

Fuel Hazards

Explosion and Fire Hazards

Engine Safety

Operating Safety Positioning the Unit

Starting the Unit

Raising and Lowering the Mast

Service Safety

Trailer Hazards

Towing Safety Hitch and Coupling

Running Lights

Wheels and Tires

Safe Towing Techniques

Reporting Trailer Safety Defects

Safety and Operating Decals

Section 2: General Information

Specifications

Unit Dimensions

Unit and Serial Number Locations

Altitude and Temperature Limitations

Component Locations Exterior

Interior

Connection Panel

Receptacle Panel

Control Panel

Genset Controller Controller Modes

Operator Pages

Maintenance Alarms

Voltage Selector Switch Lockout Function

Section 3: Operation

Pre-start Checklist

Manually Starting the Unit

AUTO (Remote) Starting the Unit

Wet Stacking

Low Idle Switch

Cold Weather Operation

Using a Booster Battery or Charger (if equipped) ..27 Parallel:

Generator Output Connections

Generator Cam Lock Connections (If Equipped)

Using the Voltage Selector Switch

Fine Voltage Adjustment

Voltage Regulator

Customer Convenience Receptacles

Main Circuit Breaker

Transfer Switch

Alternate Load Device (ALD)

Changing Exercise Timers

Shutting Down the Unit

Emergency Stop Switch

Using the ECU Override Switch

Positive Air Shutoff (PAS) Valves PAS Test Procedure

Towing the Unit

Lifting the Unit

Section 4: Maintenance

Emissions Information

Maintenance

Daily Walk Around Inspection

Belt Tensioners

General Maintenance

Engine Oil Recommendations

Coolant Recommendation

Basic Maintenance Schedule

Engine Break-In Requirements

Checking Generator Drive Plate Torque

ALD System Maintenance

Resetting Maintenance Alarms

Jack Maintenance Side-Wind Models Owner’s Manual for Mobile Generator iii

Top-Wind Models

Trailer Wheel Bearings

Section 5: Troubleshooting

General Troubleshooting

Section 6: Wiring Diagrams

Controls

Control Box (1 of 2)

Control Box (2 of 2)

Generator Cabin (1 of 2)

Generator Cabin (2 of 2)

Generator Box—VFLEX (If Equipped) iv Owner’s Manual for Mobile Generator

Section 1: Introduction and Safety

Introduction Thank you for purchasing a Generac Mobile 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 prod-ucts 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 the manual is not understood, contact your nearest GMASD, or contact Generac Mobile at 1-800-926- 9768, or Generac Mobile Technical Service at 1-800-926-9768 or www.generacmobileproducts.com with any questions or 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.

How to Obtain Service

When the unit requires servicing or repairs, contact a GMASD) for assistance. Service technicians are factory-trained and are capable of handling all service needs. For assistance locating a dealer, visit www.generacmobileproducts.com/parts-service/find-service. When contacting a GMASD about parts and service, always supply the complete model number and serial number of the unit as given on its 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 that 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:

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.

(000100a)

Consult Manual. Read and understand manual completely before using product. Failure to completely understand manual and product could result in death or serious injury.

WARNING

(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.

Owner’s Manual for Mobile Generator 1 http://www.generacmobileproducts.com http://www.generacmobileproducts.com/parts-service/find-service http://www.generacmobileproducts.com/parts-service/find-service

Introduction and Safety General Hazards

Electrical Hazards (000103)

Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury.

DANGER

(000107)

Hearing Loss. Hearing protection is recommended when using this machine.

Failure to wear hearing protection could result in permanant hearing loss.

WARNING

(000111)

WARNING

Moving Parts. Keep clothing, hair, and appendages away from moving parts. Failure to do so could result in death or serious injury.

(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.

Risk of injury. Do not operate or service this machine if not fully alert. Fatigue can impair the ability to operate or service this equipment and could result in death or serious injury. (000215a)

WARNING

(000139)

WARNING

Risk of burns. Allow engine to cool before draining oil or coolant. Failure to do so could result in death or serious injury.

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)

DANGER

Asphyxiation. Do not operate unit without a properly functioning exhaust system.

Doing so will result in death or serious injury.

(000340)

(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.

(000188)

DANGER

Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury.

DANGER

Electrocution. DO NOT use the unit if electrical cord is cut or worn through. Doing so will result in death or serious injury.

(000263a)

(000188)

DANGER

Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury.

2 Owner’s Manual for Mobile Generator

Battery Hazards

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.

Fuel Hazards

• DO NOT fill fuel tank while the engine is running.

• DO NOT operate with the fuel tank cap loose or missing.

Explosion and Fire Hazards

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.

(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)

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.

WARNING

(000163a)

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

WARNING

(000228)

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.

(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.

WARNING

Explosion and Fire. Do not smoke while refueling unit. Failure to do so could result in death, serious injury, or property or equipment damage. (000284a)

(000105)

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.

DANGER

Explosion and Fire. Fuel and vapors are extremely flammable and explosive. Keep fire and spark away. Failure to do so will result in death or serious injury. (000168)

DANGER

(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.

(000110)

WARNING

Risk of Fire. Hot surfaces could ignite combustibles, resulting in fire. Fire could result in death or serious injury.

WARNING

(000281)

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.

(000249)

WARNING

Risk of fire. Never operate engine without the air cleaner installed. Operating engine without the air cleaner could result in death or serious injury.

Owner’s Manual for Mobile Generator 3 http://batterycouncil.org http://batterycouncil.org

• DO NOT run engine indoors or in an area with poor ventilation. Make sure 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:

•Noticeable change in engine speed.

•Loss of electrical output.

•Equipment connected to the unit overheats.

•Sparking occurs.

•Engine misfires or there is excessive engine/gen-erator vibration.

•Protective covers are loose or missing.

•Ambient air temperature is above 113 °F (45 °C).

Operating Safety

Positioning the Unit

• If the unit is equipped with a frame grounding stud, follow the National Electrical Code (NEC), state, and local regulations when connecting.

Starting the Unit

Raising and Lowering the Mast

• Keep area around the unit clear of people while raising and lowering the mast.

• ALWAYS lower the mast when not in use.

• If for any reason any part of mast hangs up or winch cable develops slack while raising or lowering tower, STOP immediately! Contact a

GMASD.

CAUTION

Equipment damage. Do not clean air filter elements.

Contaminants may remain after cleaning, shortening air filter service life. Doing so could result in engine or equipment damage.

(000317)

(000260a)

High Voltage. Verify area above unit is clear of overhead wires and obstructions. Contact with high-voltage power lines will result in death or serious injury.

DANGER

(000147)

WARNING

Risk of Fire. Unit must be positioned in a manner that prevents combustible material accumulation underneath. Failure to do so could result in death or serious injury.

WARNING

Equipment and property damage. Do not operate unit on uneven surfaces, or areas of excessive moisture, dirt, dust or corrosive vapors. Doing so could result in death, serious injury, property and equipment damage.

(000250)

DANGER

Electrocution. DO NOT use the unit if electrical cord is cut or worn through. Doing so will result in death or serious injury.

(000263a)

WARNING

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. (000291)

WARNING

Electrocution. Do not set up or operate this unit if severe weather is expected. Lightning strikes can kill or cause severe injury even if you are not touching the unit. (000296)

Tipping hazard. Do not set up the unit if high winds are expected. High winds can cause the unit to tip or fall, causing severe injury or machine damage. (000594a)

WARNING

> 50 mph (80 km/h)

WARNING

(000266)

Tipping hazard. Extend the outriggers and level the unit before raising the mast. Keep the outriggers extended while the mast is up. Failure to do so could cause the unit to tip and fall and could result in death or serious injury.

WARNING

Personal Injury. Stop immediately if the mast hangs up or the winch cable develops slack. Excess slack could cause the mast to collapse, resulting in personal injury or equipment damage. (000265) 4 Owner’s Manual for Mobile Generator

Service Safety

This unit uses high voltage circuits capable of causing serious injury or death. Only a qualified and licensed electrician should troubleshoot or repair problems occurring in this equipment.

• Before servicing the unit, verify the control power switch and circuit breakers are OFF (0), and the negative (-) terminal on the battery is disconnected. DO NOT perform even routine service (oil/ filter changes, cleaning, etc.) unless all electrical components are shut down.

• ALWAYS use extreme caution when servicing this unit in damp conditions. Do not service the unit if skin or clothing is wet. Do not allow water to collect around the base of the unit.

• DO NOT wash the unit with high pressure hoses, power washers, or steam cleaners. Water may collect in unit, causing damage to electrical parts.

• Replace all missing and hard to read decals.

Decals provide important operating instructions and warn of dangers and hazards.

• Wear heavy leather gloves when handling winch cables. Never let cables slip through bare hands.

Trailer Hazards

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).

• DO NOT tow trailer using defective parts. Inspect the hitch and coupling for wear or damage.

• Before towing the trailer, verify that the weight of the trailer is equal across all tires. On trailers with adjustable height hitches, adjust the angle of the trailer tongue to keep the trailer as level as possible.

Running Lights

Verify directional and brake lights on the trailer are connected and working properly.

(000148a)

WARNING

Accidental start-up. Disconnect negative battery terminal before servicing to prevent accidental engine rotation. Failure to do so could result in death or serious injury.

(000187)

WARNING

Electrocution. Potentially lethal voltages are generated by this equipment. Render the equipment safe before attempting repairs or maintenance. Failure to do so could result in death or serious injury.

(000419)

CAUTION

Personal injury. Wear appropriate personal protective equipment at all times while operating and servicing unit. Failure to do so could result in personal injury.

WARNING

(000233a)

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.

(000231a)

Personal injury. Do not operate unit during transport.

Doing so could result in death, serious injury, or property damage.

WARNING

(000234a)

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

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

(000233a)

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.

WARNING

Property or equipment damage. Do not alter the trailer. Alterations can damage essential safety items.

Doing so could result in death, serious injury, or property or equipment damage. (000285) Owner’s Manual for Mobile Generator 5

Wheels and Tires

• Inspect trailer tires for wear and proper inflation.

• Verify wheel lug nuts are present and tightened to the specified torque.

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.

If NHTSA receives similar complaints, it may open an investigation; and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in an individual problem between you, your dealer, or Generac Mobile.

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.

6 Owner’s Manual for Mobile Generator http://www.safercar.gov http://www.safercar.gov http://www.safercar.gov http://www.safercar.gov http://www.safercar.gov http://www.safercar.gov http://www.safercar.gov

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.

ID Description ID Description

1 Lifting point 17 Connection terminal lugs

2 Do not use as a step 18 Terminal connections (voltage selector switch)

3 Coolant drain 19 Electrical ground

4 Tie-down point 20 Starting and stopping the generator

5 Engine oil drain 21 Electrical backfeed danger

6 Do not open door with engine running 22 Operating instructions

7 Electrical shock hazard 23 Read and understand owner’s manual

8 Ultra-low sulfur diesel 24 Controller buttons

9 Diesel fuel 25 Circuit breaker

10 Towing instructions 26 Neutral bonded to frame

11 Hot coolant under pressure, hot surface 27 Remote start terminal connections

12 Do not remove guard—hazards 28 Neutral

13 Secondary filter 29 Cam lock connector

14 Primary filter 30 Do not open door with engine running

15 Warning: Generator can automatically start 31 Receptacle caution

16 Various hazards—read manual — — Owner’s Manual for Mobile Generator 7 http://www.generacmobileproducts.com/

Figure 1-1. Exterior Decals

Inside door on plexiglass panel

007607 8 Owner’s Manual for Mobile Generator

Figure 1-2. Interior Decals

PRIMARY

FILTER

SECONDARY

FILTER

La génératrice peut démarrer automatiquement, ce qui peut entraîner des blessures graves. Débrancher la batterie avant de faire l’entretien.

Generator can automatically start which can cause serious injury.

Disconnect battery before servicing.

Der Generator kann automatisch anspringen und schwere Verletzungen verursachen. Vor der Instandsetzung die Batterieverbindungen lösen.

El generador puede arrancar automáticamente, lo que puede causar graves lesiones. Desconecte la batería antes de realizar el servicio técnico.

10000024178 10000023194

L1 Black L2 Red L3 Blue N White G Green

10000023694

10000022644

10000023194

La génératrice peut démarrer automatiquement, ce qui peut entraîner des blessures graves. Débrancher la batterie avant de faire l’entretien.

Generator can automatically start which can cause serious injury.

Disconnect battery before servicing.

Der Generator kann automatisch anspringen und schwere Verletzungen verursachen. Vor der Instandsetzung die Batterieverbindungen lösen.

El generador puede arrancar automáticamente, lo que puede causar graves lesiones. Desconecte la batería antes de realizar el servicio técnico.

10000024178

Inside unit on radiator fan guard

WARNING

WARNUNG

ADVERTENCIA

AVERTISSEMENT

Optional 4th Position on Voltage Selector Switch

T1 L1

T4 T7

T10 N

T2

L2

T8 T5 T9

T6

T3 L3

T11T12

L-N

L-L

L1 - L2 = 480V L1 - N = 277V L2 - L3 = 480V L2 - N = 277V L3 - L1 = 480V L3 - N = 277V N =

T4

T7

T10

T1

L1

L2T8

T2T9

T3

T6 T11

L3

T5T12 N

L-N

L-L

L1 - L2 = 208V L1 - N = 120V L2 - L3 = 208V L2 - N = 120V L3 - L1 = 208V L3 - N = 120V N =

T1

L1

T4 T7

T10 T2 L2T8 T5

T9 T6

T3

L3 T11

T12

L-LN

L-N

L-N

T4 T1

T6 T2

T12 T8 T5T3

T10 T7 T11T9L3

N L1

120V120V

240V

TERMINAL CONNECTIONS / KLEMMENBELEGUNG / CONEXIONES DE TERMINALES / BRANCHEMENTS AU TERMINAL

L1 - L2 = 240V L1 - N = 120V L2 - L3 = 240V L2 - N = 208V L3 - L1 = 240V L3 - N = 120V N =

120/

240V 3PH

277/ 480V

120/ 208V

120/ 240V

1PH

120/240V 3-PHASE

120/ 240 V

3Ø

277/ 480 V

120/ 208 V

120/ 240 V

1Ø

277/480V 3-PHASE 120/208V 3-PHASE

120/240V 1-PHASE

277/480 3Ø

120/208 3Ø 120/240

1Ø 277/480

3Ø

120/208 3Ø 120/240

1Ø

277/480 3Ø

120/208 3Ø 120/240

1Ø L1 - L3 = 240V L1 - N = 120V L2 - N = ------- L3 - N = 120V N=

Never change switch position with engine running. Results in damage to machine.

Bei laufendem Motor darf die Schalterstellung nicht verändert werden. Dies führt zur Beschädigung der Maschine.

Nunca cambie la posición del interruptor con el motor en funcionamiento. Puede causar daños a la máquina.

Ne jamais changer la position du commutateur lorsque le moteur fonctionne. Vous pourriez endommager l’appareil.

AVERTISSEMENT

ADVERTENCIA

WARNUNG

WARNING

STOP

011189

Owner’s Manual for Mobile Generator 9

Figure 1-3. Control Panel and Connection Panel Decals

Control Panel

Connection Panel

NEUTRAL (L0) BONDED TO FRAME

NULLLEITER (L0) AM RAHMEN ANGESCHLOSSEN

NEUTRO (L0) CONECTADO AL BASTIDOR

POSITION NEUTRE (L0) LORSQUE FIXÉ AU CADRE

Backside of control panel access door

ATTENTION

ATENCIÓN

VORSICHT

CAUTION

120V GFCI receptacles not for use when generator is operated at 480 V without a buck transformer.

ENGINE

SPEED

CONTROLLER

POWER

A0000705133

Do not open door with engine running.

Main circuit breaker will shunt trip (open).

292929

011190 10 Owner’s Manual for Mobile Generator

Section 2: General Information

Specifications

Description UOM MDG25IF4 With SUPERSTART® With VFLEX

Engine

Make (Model) — Isuzu® (4LE2T) Isuzu (4LE2T) Isuzu (4LE2T)

Rated Power Output hp (kW) 40 (30) 40 (30) 40 (30)

Operating Speed rpm 1,800 1,800 1,800

Fuel Consumption—100% load:

Standby, Prime gph (Lph) 2.3 (8.6), 2.0 (7.4) 2.3 (8.6), 2.0 (7.4) 2.3 (8.6), 2.0 (7.4)

Fuel Consumption—75% load:

Standby, Prime gph (Lph) 1.7 (6.5), 1.6 (6.1) 1.7 (6.5), 1.6 (6.1) 1.7 (6.5), 1.6 (6.1)

Fuel Consumption—50% load:

Standby, Prime gph (Lph) 1.2 (4.4), 1.1 (4.2) 1.2 (4.4), 1.1 (4.2) 1.2 (4.4), 1.1 (4.2)

EPA Emissions Certification Tier 4 Final 4 Final 4 Final

Battery—Voltage (Qty of Batteries) VDC (qty) 12 (1) 12 (1) 12 (1)

Battery—Rating CCA 720 720 720

Capacities

Fuel Tank—Usable gal (L) 56 (211) 56 (211) 56 (211)

Maximum Run Time—Full Load hr 28 28 28

Coolant—System gal (L) 4.4 (16.7) 4.4 (16.7) 4.4 (16.7)

Oil—Crankcase qt (L) 10.9 (10.4) 10.9 (10.4) 10.9 (10.4)

Generator

Make (Model) — Marathon Electric®

(282PSL1705)

SUPERSTART Marathon Electric (283PSL1707)

VFLEX Marathon Elec-tric (283PSL28106)

Insulation Class H H H

Poles qty 4 4 4

Voltage Regulation — Standard, ±0.5% Standard, ±0.5% Standard, ±0.5%

Frequency Hz 60 60 60

Power Output

3Ø Standby kW (kVA) 25 (31) 25 (31) 25 (31)

277/480 V A 37 37 37

120/208 V A 86 86 86

120/240 V* A 75 75 75

346/600 V A NA NA 29

3Ø Prime kW (kVA) 20 (25) 20 (25) 20 (25)

277/480 V A 30 30 30

120/208 V A 70 70 70

120/240 V* A 60 60 60

346/600 V A NA NA 24

1Ø Standby kW (kVA) 17.5 (17.5) 17.5 (17.5) 11 (11)

120/240 V A 73 73 45

1Ø Prime kW (kVA) 17.5 (17.5) 17.5 (17.5) 11 (11)

120/240 V A 73 73 45

Specifications continued on next page.

Owner’s Manual for Mobile Generator 11

General Information Unit Dimensions

Figure 2-1. Unit Dimensions

Power Factor: 3Ø, 1Ø — 0.8, 1.0 0.8, 1.0 0.8, 1.0

AC Distribution

Circuit Breaker Size A 125 125 125

Trailer

Hitch—Standard size, type 2 in (51 mm), ball 2 in (51 mm), ball 2 in (51 mm), ball

Maximum Tire Pressure psi (kPA) 65 (448) 65 (448) 65 (448)

Tires Size ST185/80D13 ST185/80D13 ST185/80D13

Axle—GVWR lb (kg) 3,100 (1,406) 3,100 (1,406) 3,100 (1,406)

Weight

Skid Mounted—Dry lb (kg) 2,010 (911) 2,081 (944) 2,051 (930)

Skid Mounted—Operating lb (kg) 2,450 (1,111) 2,521 (1,143) 2,491 (1,130)

Trailer Mounted—Dry lb (kg) 2,247 (1,019) 2,318 (1,051) 2,288 (1,038)

Trailer Mounted—Operating lb (kg) 2,771 (1,256) 2,842 (1,289) 2,812 (1,275)

Specifications are subject to change without notice.

*Power rating achieved through use of optional 4-position phase switch.

Description UOM MDG25IF4 With SUPERSTART® With VFLEX

L W H

Skid Mounted 76 in (1.93 m) 36.37 in (0.92 m) 53.5 in (1.35 m)

Trailer Mounted 139.25 in (3.53 m) 51.75 in (1.31 m) 64.75 in (1.64 m)

011143

L

H

W

L

H

W

12 Owner’s Manual for Mobile Generator

Unit and Serial Number Locations See Figure 2-2 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 2-2. 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 (3,048 m).

If the unit is operated in an ambient condition above 120 °F (49 °C) at full power, the coolant temperature will exceed the maximum allowable limit of 203 °F (95 °C) and cause the engine to shut down.

Maximum Altitude Maximum Air TemperaturePrime Power Standby Power

10,000 ft (3,048 m) 4,500 ft (1,371 m) 120 °F (49 °C)

011191

A

B

Owner’s Manual for Mobile Generator 13

Component Locations

Exterior

Figure 2-3. Exterior Components

A Hot air/exhaust duct M Fuel drain (unit underside)

B Coolant fill port N Coolant drain

C Unit lift point O Engine oil drain

D Telemetry (if equipped) P Engine access door

E Fuel fill port Q Breaker and connection panel access door

F Tie-down point (4 locations) R Emergency stop switch

G Generator access door S Stabilizer jack (2 locations) (if equipped)

H Engine access door T License plate holder

I Side marker light (4 locations) U Tail light (2 locations)

J Tool box (if equipped) V Auxiliary fuel inlet (if equipped)

K Battery for breakaway brakes (if equipped) W Control panel access door

L Tongue jack

011192

C D

F

V

N O

B

K

U

R

E

I J

S

L

T

M

A

G

H

P

Q

W

14 Owner’s Manual for Mobile Generator

Interior

Figure 2-4. Interior Components

A Engine oil fill J Secondary fuel filter

B Battery charger (if equipped) K Fuel pump

C Generator phase switch L Primary fuel filter

D VFLEX switch (if equipped) M Coolant overflow container

E Generator N Battery disconnect switch

F Air filter O Engine oil filter

G Battery P Connection panel

H Block heater (if equipped) Q Receptacle Panel

I Engine exhaust R Control panel

011193

C

F

G

I

D

E

J

L

M

P

R

O

N

K

A

Q

B

H

Owner’s Manual for Mobile Generator 15

Connection Panel

Figure 2-5. Connection Panel

A Main circuit breaker E Connection lug (5 locations)

B Panel light F Safety shutoff switch

C Service lights switch G Cam lock receptacle (5 locations) (if equipped)

D Neutral bonding bar H Remote start terminal block

D

A B

E

G

C

H

011194

F

16 Owner’s Manual for Mobile Generator

Receptacle Panel

Figure 2-6. Receptacle Panel

A 50 A circuit breaker (3 locations) E LED light switch

B 20 A circuit breaker (2 locations) F 120/240 V twist-lock receptacle (3 locations)

C Block heater power supply (if equipped) G Battery charger power supply (if equipped)

D 120 V GFCI receptacle (2 locations)

011195

A B

F

E

D

CG

Owner’s Manual for Mobile Generator 17

Control Panel

Figure 2-7. Control Panel

A Genset controller E Fuel transfer pump switch

B Door latch F Interior cabin lights switch

C Voltage adjustment dial (potentiometer) G Low idle switch

D [not used] H Controller power switch

011196

A

C

B

DEFGH

18 Owner’s Manual for Mobile Generator

Genset Controller See Figure 2-8. The genset controller displays real-time operational data, monitors functions of the generator and engine, shuts down the unit for certain fault conditions, displays fault data, and retains up to 250 unit performance events.

The controller is programmable. It can automatically start and stop the genset according to schedule, fault condition, or load demand.

Figure 2-8. Genset Controller—Deep Sea® Model DSE7310 MKII

A Navigation buttons J Positive air shutoff (PAS) valve test switch LED (if equipped)

B Screen K PAS valve test switch (if equipped)

C Indicator LED (4 locations) L MANUAL Mode LED

D Transfer to Generator button M MANUAL Mode button

E Generator Available LED N Engine STOP/RESET Mode button

F Engine START button O Engine STOP/RESET Mode LED

G Alarm Mute and Lamp Test button P Open Generator button

H AUTO Mode LED Q Open Generator LED

I AUTO Mode button R RS232 serial port (not shown—controller backside)

010417

D

F

GI

N

P

A B C

M K HL

O

E

Q

J

R

Owner’s Manual for Mobile Generator 19

(A) Navigation Buttons See Figure 2-9. Used to navigate the operator pages.

Figure 2-9. Navigation Buttons

Navigate the operator pages as follows.

(B) Controller Screen

The controller screen displays various operational data for unit monitoring, diagnosing, and troubleshooting. See Operator Pages for more information.

(C) Indicator LEDs See Figure 2-10. Each LED indicates a condition that impedes normal unit function.

Figure 2-10. Indicator LEDs

If an indicator LED is illuminated, resolve the condition to restore normal unit function, as described in table below.

NOTE: When a condition is resolved, the corresponding indicator LED switches off.

NOTE: If unable to resolve a condition as recommended, contact a GMASD.

(D) Transfer to Generator Button

Only applies to MANUAL mode.

Controls operation of generator load switch, when the generator is available.

NOTE: In units equipped with a manual breaker, this function is not available.

Status is indicated by the Close Generator LED.

(E) Close Generator LED

• When illuminated, cam locks and lugs are enabled.

• When not illuminated, cam locks and lugs are disabled.

(F) Engine Start Button

When STOP/RESET mode is active, the Engine Start button switches on the engine ECU but does not start the engine. Uses in this context are to check status of the CAN communication and to prime the engine.

When MANUAL mode is active, the Engine Start button starts the generator.

NOTE: In AUTO or STOP mode, the Engine Start button activates the ECU.

(G) Alarm Mute and Lamp Test Button

Stops the audible alarm and illuminates functional controller LEDs.

To test the LEDs, press and hold button. All LEDs illuminate. When button is released, the LEDs switch off.

NOTE: If an LED does not illuminate when button is pushed, the LED is not functioning.

(H) AUTO Mode LED

• When illuminated, AUTO mode is active.

• When not illuminated, AUTO mode is not active.

(I) AUTO Mode Button

Switches the mode to AUTO. See Controller Modes for important guidelines.

Status is indicated by the AUTO Mode LED.

(J) PAS valve test switch LED (if equipped)

When illuminated, PAS test is in progress.

► View next

◄ View previous

▲ Scroll up current

▼ Scroll down current

Select highlighted item

A Low Load indicator LED.

• Indicates genset has operated at less than 30% capacity for more than 15 minutes.

• Resolve by increasing electrical load. If unable to operate genset at more than 30% load, use a smaller generator.

B Lug Door Open indicator LED.

• Indicates lug-box door is open.

• Resolve by closing lug-box door. If condition remains unresolved, inspect lug-box door safety switch for proper operation.

010418

010419

A

B

C

D

C Emergency Stop indicator LED.

• Indicates Emergency Stop switch is active (pushed in).

• Resolve by deactivating (pulling out) Emergency Stop switch.

D Shutdown indicator LED.

• Indicates a shutdown alarm is present.

• Resolve by resolving shutdown condition.

20 Owner’s Manual for Mobile Generator

(K) PAS valve test switch (if equipped)

When PAS test is active, the PAS is cycled to verify function.

(L) MANUAL Mode LED

• When illuminated, MANUAL mode is active.

• When not illuminated, MANUAL mode is not active.

(M) MANUAL Mode Button

Switches the mode to MANUAL. See Controller Modes for important guidelines.

Status is indicated by the MANUAL Mode LED.

(N) Engine STOP/RESET Mode Button

Switches the mode to STOP. See Controller Modes for important guidelines.

Status is indicated by the STOP/RESET Mode LED.

(O) Engine STOP/RESET Mode LED

• When illuminated, STOP mode is active.

• When not illuminated, STOP mode is not active.

(P) Open Generator Button

The Open Generator button is only active in the Manual Mode and allows the operator to open the generator load switch when a motorized breaker is used. Pressing the Open Generator button when the Generator is on load, the generator load switch is opened.

NOTE: In units equipped with a manual breaker, limited function is available.

Status is indicated by the Open Generator LED.

(Q) Open Generator LED

• When illuminated, cam locks and lugs are disabled.

• When not illuminated, cam locks and lugs are enabled.

Controller Modes

MANUAL Mode

MANUAL mode is distinguished by full operator control of unit start-up and shut-down functions, and by full operator control of generator load and unload functions.

AUTO Mode

AUTO mode is distinguished by automation of unit start-up and shut-down functions, and by automation of generator load and unload functions.

AUTO mode utilizes the remote start connections. For remote starting procedures, see Section 3, Operation.

AUTO mode utilizes a programmed schedule, which can be modified.

NOTE: To modify the AUTO mode programmed schedule, use the Deep Sea Configuration Suite software.

STOP/RESET Mode

STOP/RESET mode is distinguished by the following:

• Unloads the generator.

• Clears active alarms—if alarm conditions have been resolved.

• Shuts down the unit.

• Deactivates the Engine Start button.

• Stops all AUTO mode automation (if applicable).

• Controller power remains ON.

Switching Mode

1. Verify controller is ON.

NOTE: The engine can be running but it is not required.

2. Stop drawing power from the unit: Stop using equipment plugged into receptacles, cam locks, and anything connected to the lugs.

3. See Figure 2-8. Press the desired Mode button.

The mode immediately changes.

Operator Pages

Operator pages display various data for unit monitoring, diagnosing, and troubleshooting. The pages are:

• Status page

• Engine page

• Generator page

• Alarm page

• ECU DTC page

• Event Log page

• Serial Port page

• Program File Information page

• About page

NOTE: Operator pages are available after normal unit start-up.

NOTE: Operator pages are view-only. No settings can be added, modified, or deleted.

Generator Page

Figure 2-11. Generator Page 010422 Owner’s Manual for Mobile Generator 21

The Generator page displays the following generator data, in real time (press ▲ or ▼ to scroll).

• Voltage (ph-N)

• Voltage (ph-ph)

• Frequency

• Current (A)

• Load ph-N (kW)

• Total load (kW)

• Load ph-N (kVA)

• Total load (kVA)

• Single phase power factors

• Power factor average

• Load ph-N (kvar)

• Total load (kvar)

• Accumulated load (kWh, kVAh, kvarh)

• Loading scheme

• Phase rotation

• Nominal

• Active configuration

NOTE: The list above varies, according to generator make, model, and features.

NOTE: As possible, distribute electrical loads equally among generator lines. Minor load imbalances (10% or less) usually do not cause problems. When loading generator, observe the load (amperage) on each line.

Alarms Page

Figure 2-12. Alarm Page

The Alarms page displays active warnings and active alarms, including engine DTCs.

ECU DTC Page

Figure 2-13. ECU DTC Page—Current DTCs

The ECU Current DTC page displays active ECU DTCs.

Press ► to view previous ECU DTCs.

NOTE: See engine manual for information on ECU DTCs.

NOTE: All DTCs display on the ECU DTC page. Some DTCs may also display in the Event Log, with similar descriptions as those displayed on the ECU DTC page.

Event Log Page

Figure 2-14. Event Log Page

The Event Log page displays current and previous alarms.

• Event Log capacity is 250 alarm events. After 250 events are logged, each new event overwrites the oldest.

• Only alarms are logged.

• Newest event displays at top of log; oldest at bottom.

010423

010424

010425 22 Owner’s Manual for Mobile Generator

Serial Port Page

The Serial Port page displays information about the RS232 serial port, which enables data transfers. If an external modem is connected to the serial port, modem information also displays.

NOTE: The Serial Port page display may vary, in accordance with controller configuration.

See Figure 2-15. If a modem is connected to the controller, Modem displays, as illustrated.

Figure 2-15. Serial Port Page. If modem is not connected, RS232 displays in place of Modem.

See Figure 2-16. When the controller can accept a data transfer, Modem Ready displays, as illustrated.

Figure 2-16. Serial Port Page—Modem Ready

Program File Information Page

Figure 2-17. Program File Information Page

The Program File Information page displays the following controller information.

• Controller model unit

• Program file name

• Program PN

• Program version

About Page

Figure 2-18. About Page

The About page displays various general information about the unit and controller, as illustrated.

Maintenance Alarms Maintenance alarms indicate a regular-maintenance service interval is expired. To resolve the condition, perform the indicated service, then re-set the corresponding service interval.

To re-set a service interval:

1. Display the Engine page.

2. Scroll (▲ or ▼) until the appropriate service inter-val is highlighted.

NOTE: The expired interval displays on the Alarm page.

3. Press and hold the Engine STOP/RESET Mode button until ###* hr service changes to 0 hr service.

*A number displays. The value varies according to what service interval is highlighted.

010426

010427

010428

010429 Owner’s Manual for Mobile Generator 23

Voltage Selector Switch

The voltage selector mechanically configures the generator main windings. The unit is equipped with either a three- or four-position switch. Available configurations for each are shown in the table below.

Lockout Function

The voltage selector switch is equipped with a lockout mechanism. When engaged, the switch is locked in place, preventing configuration changes.See Using the Voltage Selector Switch for instructions on switching the voltage.

3-Position Switch

4-Position Switch

Available Configurations

• Hi wye

• Low wye

• Zig zag

• Hi wye

• Low wye

• Zig zag

• Delta

(000302)

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.

24 Owner’s Manual for Mobile Generator

Section 3: 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.

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

Operating the unit in MANUAL mode allows the operator to start and stop the unit from the controller using the engine START and STOP buttons.

To start unit in MANUAL mode:

1. Set controller power to ON (I). The controller begins its boot sequence. When controller is ready, the Home page displays.

NOTE: The controller boots in STOP mode, as indicated at the top of the screen.

2. Press MANUAL Mode button.

NOTE: If starting the unit in cold ambient temperatures, it is recommended to start the unit at low idle, and allow the engine to heat up the lubricating oil. For more information, see Low Idle Switch.

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

3. Press engine START (I) button. The controller begins the engine startup sequence and starts the engine—provided no engine faults prevent starting.

NOTE: It takes several seconds for the engine to warm (run smoothly and reach its operating speed). During warming, the screen displays a different voltage than the voltage selector switch.

4. If the engine does not start within three crank attempts, the controller will display the failed 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.

(000100a)

Consult Manual. Read and understand manual completely before using product. Failure to completely understand manual and product could result in death or serious injury.

WARNING

WARNING

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. (000291)

(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.

(000103)

Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury.

DANGER

WARNING

(000281)

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.

Owner’s Manual for Mobile Generator 25

Operation NOTE: Engine preheat is controlled by the ECU.

5. When the engine starts, it accelerates to operating speed. If the Low Speed Idle switch is ON, the engine accelerates to the low idle speed set-point.

IMPORTANT NOTE: Allow the engine to warm for approximately 10 minutes. Failure to properly warm the engine prior to loading can cause premature engine wear or failure.

6. When engine is warm, turn OFF the Low Idle Speed switch.

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

8. Verify the AC output voltage is correct. See Fine Voltage Adjustment.

9. Verify generator frequency (Hz) is correct on the generator screen. The frequency should be the rating specified on the unit data tag.

10. 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 allows the operator to start and stop the unit by closing the remote start contacts (on the lug panel), programming a schedule stop sequence in the controller, or through a telemetry signal (if equipped).

NOTE: When in AUTO mode, the STOP button can be pressed to stop the unit.

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 Shutting Down the Unit, then proceed as follows:

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

2. To check the remote start circuit, remove the wires from the remote start terminal block. Press the AUTO button, and the display screen will show auto mode at the bottom 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 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 runs the stop sequence. 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. Secure the unit by closing and locking all access doors.

7. The unit is now ready for remote starting.

See…