Owner’s Manual Diesel Generator MDG75DF4 • MDG100DF4 006226 For technical assistance contact: www.generacmobileproducts.
Use this page to record important information about your unit. Unit Model No. Unit Serial No. Engine Model No. Engine Serial No. Generator Model No. Generator Serial No. Date Purchased Record the information found on your unit data label on this page. See Unit and Serial Number Locations. Engine and generator serial numbers are located on separate data plates affixed to the engine and generator respectively.
Table of Contents Section 1: Introduction and Safety Section 3: Operation Introduction ..................................................................1 Read This Manual Thoroughly ....................................1 Pre-start Checklist .....................................................25 How to Obtain Service .................................................1 Safety Rules .................................................................1 Manually Starting the Unit ..............................
Section 4: Maintenance Emissions Information .............................................. 39 Maintenance ............................................................... 39 Daily Walk Around Inspection .................................. 39 Belt Tensioners .......................................................... 39 General Maintenance ................................................ 39 Engine Oil Recommendations .................................. 40 Recommended Oil Types ..................................
Section 1: Introduction and Safety Introduction Safety Rules 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 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.
Introduction and Safety General Hazards WARNING DANGER Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury. (000103) 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) WARNING DANGER Asphyxiation.
Introduction and Safety Electrical Hazards Lifting Hazards DANGER WARNING 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. (000145) DANGER Personal injury. Failure to properly connect lifting cables, chains, or straps could result in death, serious injury, or property damage. (000346) WARNING Electrocution.
Introduction and Safety Battery Hazards Fuel Hazards DANGER Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury. (000188) 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. (000192) DANGER WARNING Explosion. Batteries emit explosive gases while charging. Keep fire and spark away.
Introduction and Safety Operating Safety Positioning the Unit 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. (000234a) • 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.
Introduction and Safety Safety and Operating Decals See Figure 1-1 through Figure 1-4. 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. 6 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.
Introduction and Safety DANGER 1 Lock doors. Access can cause electric shock or injury. 5 GEFAHR Türen schließen. Zugang kann zu Stromschlag oder Verletzung führen. PELIGRO Trabe las puertas. El acceso puede causar descargas eléctricas o lesiones. DANGER Verrouiller les portes. L’accès peut entraîner une électrocution ou des blessures. 10 2 9 ULTRA LOW SULFUR FUEL ONLY 1/2” NPT ENGINE OIL DRAIN 3 1/2” NPT ENGINE COOLANT DRAIN 4 6 PJ NJ 7 1 DANGER 8 Lock doors.
Introduction and Safety WARNING WARNING Never change switch position with engine running. Results in damage to machine. WARNUNG Niemals schlter unstellen wenn motor läuft. Verursacht beschädigung des gerätes. ADVERTENCIA 16 Nunca cambie la posicion del interruptor al estar marchando el motor. Ya que esto podria conducir a daños en el equipo. DANGER GEFAHR PELIGRO DANGER AVERTISSEMENT Ne jamais changer la position de l’interrupteur pendant que le moteur est en marche.
Introduction and Safety WARNING WARNING 11 11 WARNUNG ADVERTENCIA WARNUNG AVERTISSEMENT ADVERTENCIA AVERTISSEMENT WARNING Generator can automatically start which can cause serious injury. Disconnect battery before servicing. WARNUNG Aggregat kann automatisch starten und körperliche verletzung verursachen. Vor servicearbeit batterie abklemmen. 17 ADVERTENCIA Generador puede arrancar automaticamente y causar lesiones personales. Desconecte la bateria antes de prestar servicio.
Introduction and Safety WARNING Generator can automatically start which can cause serious injury. Disconnect battery before servicing. WARNUNG 17 Der Generator kann automatisch anspringen und schwere Verletzungen verursachen. Vor der Instandsetzung die Batterieverbindungen lösen. ADVERTENCIA El generador puede arrancar automáticamente, lo que puede causar graves lesiones. Desconecte la batería antes de realizar el servicio técnico.
Section 2: General Information Specifications Description Unit of Measure MDG75DF4 MDG100DF4 — 4 4 Fuel Consumption—100% prime gph (Lph) 4.85 (18.39) 6.01 (22.72) Fuel Consumption—75% prime gph (Lph) 3.74 (14.18) 4.51 (17.07) Fuel Consumption—50% prime gph (Lph) 2.63 (9.95) 3.17 (12.02) DEF Consumption—100% prime gph (Lph) 0.21 (0.79) 0.26 (0.98) DEF Consumption—75% prime gph (Lph) 0.16 (0.60) 0.19 (0.73) DEF Consumption—50% prime gph (Lph) 0.12 (0.45) 0.14 (0.
General Information Description Unit of Measure MDG75DF4 MDG100DF4 hr 30 24 A 300 400 — 3 in. ring 3 in. ring psi (kPA) 65 (448) 65 (448) Maximum Run Time 24 Hour Tank AC Distribution Circuit Breaker Size Trailer Hitch—Standard Maximum Tire Pressure Specifications are subject to change without notice. Unit Dimensions B A C B A C 006227 Figure 2-1. Unit Dimensions Skid Mounted Trailer Mounted 12 A B C 40 in (1.02 m) 69 in (1.75 m) 62 in (1.57 m) 80 in (2.03 m) 119 in (3.
General Information Component Locations Interior and Exterior D E F C G B A H L I J M K N O R Q P S T 006228 Figure 2-2.
General Information Control Panel A B C S D R E D C Q P F O G H N 006229b M L K J I Figure 2-3.
General Information Genset Controller The controller is programmable. It can automatically start and stop the genset according to time schedule, fault condition, or load demand. See Figure 2-4. 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. A B C R Q P D E O N F M L K J I H G 010417 Figure 2-4.
General Information (A) Navigation Buttons See Figure 2-5. Used to navigate the operator pages. C Emergency Stop indicator LED. • Indicates Emergency Stop switch is active (pushed in). • Resolve by deactivating Emergency Stop switch. D 010418 out) Shutdown indicator LED. • Indicates a shutdown alarm is present. • Resolve by resolving shutdown condition. Figure 2-5. Navigation Buttons NOTE: If unable to resolve a condition as recommended, contact a GMASD. Navigate the operator pages as follows.
General Information (J) [not used] be modified. This button is inactive. NOTE: To modify the AUTO mode programmed schedule, use the Deep Sea Configuration Suite software. (K) [not used] This LED is inactive. STOP Mode STOP mode is distinguished by the following: (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.
General Information ECU DTC Page Generator Page 010422 010424 Figure 2-7. Generator Page Figure 2-9. ECU DTC Page—Current DTCs The Generator page displays the following generator data, in real time (press ▲ or ▼ to scroll). The ECU Current DTC page displays active ECU DTCs. Press ► to view previous ECU DTCs. NOTE: See engine manual for information on ECM DTCs.
General Information About Page 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 2-11. If a modem is connected to the controller, Modem displays, as illustrated. 010426 Figure 2-11. Serial Port Page.
General Information Unit and Serial Number Locations Diesel Exhaust Fluid (DEF) See Figure 2-15 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.
General Information DEF Storage Guidelines DEF Tank Refilling WARNING WARNING Risk of poisoning. Do not ingest diesel exhaust fluid. Seek medical attention immediately if consumed. Failure to do so could result in serious injury. (000334) Personal injury. Avoid prolonged contact with skin. Wash skin thoroughly with soap and water. Remove contaminated clothing and wash before reuse. Seek medical attention if skin becomes irritated. Failure to do so could result in personal injury.
General Information Selective Catalytic Reduction (SCR) Monitoring This unit is equipped with a selective catalytic reduction (SCR) system to meet Tier 4 EPA emissions standards. This section gives an explanation of the indicators that are displayed on the SCR status page of the engine tab.
General Information Voltage Selector Switch 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) The voltage selector switch mechanically configures the main windings of the generator to provide a Hi Wye, Low Wye, Zig Zag or Delta configuration providing single and three phase voltage output to the main breaker.
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Section 3: Operation Pre-start Checklist Verify all electrical connections at the connection 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 the voltage selector switch is set to the desired 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.
Operation the remote start switch (transfer switch) to the remote start terminal block. NOTE: Engine preheat is controlled by the ECU. 4. 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. 5.
Operation NOTE: If any units are in parallel, do not disconnect the MSC cable. CAP CAP Low Idle Switch 002859a Figure 3-3. Three or More Units in Parallel Manual Parallel 1. Verify the units to be paralleled are OFF. 2. Secure all electrical connections to each unit and a common bus. Verify all wiring is properly color coded or labeled prior to connection. Any crossed connections will prevent units from paralleling. 3. Connect MSC cable(s) and terminating plugs (resistors) to the end units. 4.
Operation Mini mXP &UDQNLQJ 530 A B C D E F CAUTION 140 ÛF Û& 130 ÛF Û& 115 ÛF Û& 108 105 ÛF Û) Û& Û& 103 ÛF Û& See Figure 3-5. A 12 volt booster battery can be connected in parallel with batteries on the unit to aid in cold weather starting. ALWAYS use heavy-duty jumper cables. 100 ÛF Û& Parallel: 100 ÛF Û& 100 ÛF Û& Equipment damage. Do not make battery connections in reverse. Doing so will result in equipment damage.
Operation Generator Output Connections 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. (000237) 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. DANGER Electrocution.
Operation The unit may be equipped with cam lock connections 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.
Operation A D On/I On/I Off/O Off/O B C 006234 Figure 3-8. Receptacle and Breaker Locations A 20A circuit breaker (2) B 50A Circuit breaker (3) C 120/240V twist-lock receptacle (3) D 120V GFCI receptacle (2) 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).
Operation Cleaning is complete when the regeneration indicator remains off. Disabling Automatic (AUTO) Exhaust AfterTreatment Cleaning The auto exhaust after-treatment cleaning feature should always be enabled unless doing so would cause an unsafe working environment. In the event that an unsafe working environment occurs, proceed as follows to disable the auto exhaust after-treatment cleaning feature: 1. On the control panel, set the EXHAUST FILTER CLEANING switch to REGENERATION DISABLED (O). 2.
Operation transfer switch automatically returns the load back to the normal source when power is restored back to operating levels. F See Figure 3-11. Four components comprise the extended run fuel and DEF system. B A Using Extended Run Fuel and DEF System (If Equipped) C E A D B 002807 D Figure 3-10.
Operation 5. Connect electrical harness, provided with external DEF tank, to bulkhead connector (D). 6. Switch the system enable switch (C) to ON. NOTE: Fluid level in each on-board tank determines when the respective pump switches on and off. 2. Access the scheduler options section. Within this section, the scheduler can be enabled, run mode selected, and load mode selected.
Operation down will not create any hazards by accidentally turning off equipment that needs to be kept on (pumps, compressors, lights, and so forth). 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.
Operation 6. Check for proper inflation of the trailer tires. Proper inflation is specified in Specifications. To Close the Front Hood WARNING Crushing Hazard. Do not attempt to close the hood from sides of unit. Failure to close hood correctly could result in serious injury or equipment damage. (000301) 1. Verify the skid is free of debris and all personnel are clear of unit. 2. While standing at the front of the unit, slowly push the hood forward until firmly closed. 7. Check the wheel lugs.
Operation Lifting the Unit Tying Down the Unit WARNING Personal injury. Failure to properly connect lifting cables, chains, or straps could result in death, serious injury, or property damage. 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 3-16. Use the tie-down points (A) as shown. (000346) WARNING Personal Injury.
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Section 4: Maintenance Emissions Information General Maintenance For emissions information, see the OEM diesel engine manual. 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, and so forth) unless all electrical components are shut off.
Maintenance • 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. Coolant Recommendation DANGER Risk of poisoning. Do not use mouth to siphon coolant. Doing so will result in death or serious injury.
Maintenance 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.
Maintenance 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. John Deere engines are supplied with engine break-in oil from the factory. Extra care during the first 100-500 hours of engine operation will result in better performance and longer engine life. Do not exceed 500 hours of operation with the break-in oil.
Maintenance Disposal of DEF Large amounts of DEF should be contained. If large spills occur, contact local environmental authorities for assistance with clean up. If a substantial quantity of DEF is not within specification, contact the DEF supplier for assistance with disposal. Do not dump large quantities of DEF onto the ground or send DEF to wastewater treatment facilities. Top-Wind Models • Apply a lightweight oil to the screw stem. Oil Grease Grease Check Generator Drive Plate Torque 1.
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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 GMASD. Problem Possible Cause Solution Low Fuel Level Shutdown Low fuel level Check fuel level in LCD window of controller.
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Section 6: Wiring Diagrams Wiring Diagrams Owner’s Manual for Mobile Generator 47
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Part No. A0000393907 Rev. A 2/28/2020 ©2020 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.
