Owner’s Manual Diesel Generator MDG150DF4 • MDG175DF4 • MDG250DF4 SN ____________ and higher 003574 For technical assistance contact: www.generacmobileproducts.
Use this page to record important information about your unit Unit Model No. 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. Unit Serial No. Engine and generator serial numbers are located on separate data plates affixed to the engine and generator. Engine Model No.
Table of Contents Section 1: Introduction and Safety Section 3: Operation Introduction ..................................................................1 Read This Manual Thoroughly ....................................1 How to Obtain Service .................................................1 Pre-start Checklist .....................................................29 Safety Rules .................................................................1 Manually Starting the Unit ..............................
Resetting the Maintenance Alarms .......................... 46 Testing DEF ................................................................ 46 DEF Tank Cleaning .................................................... 47 Disposal of DEF ......................................................... 47 Checking Generator Drive Plate Torque ................. 47 Jack Maintenance ...................................................... 47 Side-Wind Models .....................................................
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 WARNING Electrocution. Water contact with a power source, if not avoided, will result in death or serious injury. (000104) DANGER 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 Safe Towing Techniques • Practice turning, stopping and backing up in an Positioning the Unit area away from heavy traffic prior to transporting 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.
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.
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Introduction and Safety WARNING 13 18 WARNUNG ADVERTENCIA AVERTISSEMENT Generator can automatically start which can cause serious injury. Disconnect battery before servicing. 17 Der Generator kann automatisch anspringen und schwere Verletzungen verursachen. Vor der Instandsetzung die Batterieverbindungen lösen. 14 El generador puede arrancar automáticamente, lo que puede causar graves lesiones. Desconecte la batería antes de realizar el servicio técnico.
Introduction and Safety 22 Improper connection of generator to a building’s electrical system can allow electrical current from the generator to backfeed into utility lines. This may result in electrocution of utility workers, fire or explosion. Connections to a building’s electrical system must be made by a qualified electrician and comply with all applicable laws and electrical codes.
Introduction and Safety STARTING THE GENERATOR DAS STARTEN DES GENERATORS COMIENZO DEL GENERADOR COMMENCEMENT DU GÉNÉRATEUR 1. CONTROL POWER SWITCH “ON” VOLTAGE REGULATION 34 2. PUSH ENGINE START “I” STOPPING THE GENERATOR DAS AUFHÖREN DES GENERATORS PARADA DEL GENERADOR ARRÊT DU GÉNÉRATEUR 1. PUSH ENGINE STOP “O” CONTROLLER POWER 2. CONTROL POWER SWITCH “OFF” 31 CONTROLLER POWER Read and understand the supplied operator’s manual before operating this machine.
Section 2: General Information Specifications Description UOM MDG150DF4 MDG175DF4 MDG250DF4 — John Deere® (6068HFG05) John Deere (6068HFG05) John Deere (6068HFG06) hp (kW) 196 (146) 235 (175) 295 (220) rpm 1,800 1,800 1,800 Fuel Consumption—100% Prime gph (Lph) 8.7 (33.3) 10.2 (38.6) 13.9 (52.8) Fuel Consumption—75% Prime gph (Lph) 7.1 (26.8) 8.4 (31.8) 10.4 (39.3) Fuel Consumption—50% Prime gph (Lph) 5.25 (19.8) 6.3 (23.8) 7.2 (27.4) DEF Consumption—100% Prime gph (Lph) 0.
General Information Description UOM MDG150DF4 MDG175DF4 MDG250DF4 kW (kVA) 120 (150) 140 (175) 200 (250) 480V A 180 210 301 208V A 416 486 694 1Ø Standby kW (kVA) 120 (120) 140 (140) 200 (200) 240V A 500 583 833 kW (kVA) 120 (120) 140 (140) 200 (200) A 500 583 833 Make (Model) — Marathon Electric (431PSL6611) Marathon Electric (431PSL6612) Marathon Electric (432PSL6613) Frequency Hz 60 60 60 3Ø Standby kW (kVA) 144 (180) 160 (200) 220 (275) 480V A 218 2
General Information Description UOM MDG150DF4 MDG175DF4 MDG250DF4 Coolant—Including Engine gal (L) 16.7 (63.2) 16.7 (63.2) 16.7 (63.2) Oil—Including Filter gal (L) 8.6 (32.5) 8.6 (32.5) 8.6 (32.5) Standard Fuel Tank hr 39.4 33.6 24.7 Optional Fuel Tank hr 58.9 50.3 36.9 A 600 700 900 Size, Type 3 in (76.2 mm), Ring 3 in (76.2 mm), Ring 3 in (76.
General Information Unit Dimensions H L W H L W 004418 Figure 2-1. Unit Dimensions L W H Equipped With Standard Fuel Tank Skid Mounted 145 in (3.7 m) 60 in (1.5 m) 85 in (2.2 m) Trailer Mounted 208 in (5.3 m) 86 in (2.2 m) 104 in (2.6 m) Equipped With Optional Fuel Tank 14 Skid Mounted 145 in (3.7 m) 60 in (1.5 m) 92 in (2.3 m) Trailer Mounted 208 in (5.3 m) 86 in (2.2 m) 111 in (2.
General Information Unit ID and VIN Tag 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 the tags. Record the information from the tags in the event the tags are lost or damaged. When ordering parts or requesting assistance, information from the tags may be needed. B A 006429 Figure 2-2.
General Information Component Locations Exterior C B A D E F G H I J K P O L N M 011134 Figure 2-3.
General Information Interior C D E B A F G H J N I K M L 011135 Figure 2-4.
General Information Connection Panel A C A B E D F G O H N I L M K 003580 J Figure 2-5.
General Information Control Panel A B I C H G F E D 011136 Figure 2-6.
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 2-7. 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 2-7.
General Information (A) Navigation Buttons See Figure 2-8. Used to navigate the operator pages. C Emergency Stop indicator LED. • Indicates Emergency Stop switch is active (pushed in). • Resolve by deactivating (pulling out) Emergency D 010418 • Indicates a shutdown alarm is present. • Resolve by resolving shutdown condition. Figure 2-8. Navigation Buttons NOTE: If unable to resolve a condition as recommended, contact a GMASD. Navigate the operator pages as follows. ► ◄ ▲ ▼ Stop switch.
General Information This button is inactive. AUTO mode utilizes a programmed schedule, which can be modified. (K) [not used] NOTE: To modify the AUTO mode programmed schedule, use the Deep Sea Configuration Suite software. (J) [not used] This LED is inactive. (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 2-10. Generator Page Figure 2-12. 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 2-14. If a modem is connected to the controller, Modem displays, as illustrated. 010426 Figure 2-14. Serial Port Page.
General Information Diesel Exhaust Fluid (DEF) NOTE: Unit does not ship from factory with DEF in tank. DEF Specification CAUTION Equipment damage. Do not alter DEF. Use approved DEF only. Failure to do so could cause equipment damage. (000337) Diesel exhaust fluid (DEF) is a high-purity liquid that is injected into the exhaust system of SCR engines. Maintaining the purity of DEF is important to avoiding malfunctions in the SCR system.
General Information Refilling DEF Tank WARNING 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. (000338a) CAUTION Equipment Damage. Immediately clean any surfaces with water that come in contact with diesel exhaust fluid. Failure to do so could result in equipment damage.
General Information Figure 2-18. DPF Regeneration Lamps Voltage Selector Switch NOTE: See Using Voltage Selector Switch for more information. 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 mechanically configures the generator main windings. The unit is equipped with either a 3- or a 4-position switch.
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Section 3: Operation Pre-start Checklist Verify the voltage selector switch is set to the desired 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 emergency stop switch is pulled out. Verify the radiator and surrounding shroud are clear WARNING Consult Manual. Read and understand manual completely before using product.
Operation 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.
Operation Parallel Setup and Operation (If Equipped) 5. Connect two wire start signal (dry contact closure) to all the generators on the MSC network. The contact closure will be in parallel. This system is designed to work with generators that are connected on the mobile switching center (MSC) network only and not with the utility or any other independent power source. All other power sources must be isolated from the MSC network to prevent potential damage due to power sources closing out of phase. 6.
Operation weather starting aids are required at temperatures below -13 °F (-25 °C) or at altitudes above 5,000 ft (1,500 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.
Operation 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).
Operation Generator Cam Lock Connections (If Equipped) DANGER 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. (000156) 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) Electrocution.
Operation Fine Voltage Adjustment A See Figure 3-8. Adjust fine voltage with the fine voltage potentiometer (A). Voltage adjustment range is ±10%. A B D C 004866 Figure 3-9. Receptacle and Breaker Locations 011136 Figure 3-8. Fine Voltage Potentiometer Voltage Regulator The 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.
Operation Main Circuit Breaker See Figure 3-10. The main circuit breaker is located on the main control panel. 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.
Operation Enable Exhaust After-Treatment Cleaning If the environment no longer requires the exhaust aftertreatment cleaning function to be disabled, and there are no alarms present on the SCR status screen, the auto exhaust after-treatment cleaning function should be enabled. Proceed as follows to enable the auto exhaust after-treatment cleaning feature: 1. Open the control door and locate the switch labeled REGEN INHIBIT. 2. Set the switch to ON/AUTO (I/O). 3.
Operation Changing Exercise Timers Emergency Stop Switch If exercise timers or scheduled runs are needed, contact a GMASD for assistance. 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.). CAUTION Equipment Damage.
Operation Towing the 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) 8 1 6 3 4 5 2 7 WARNING Personal injury. Do not operate unit during transport. Doing so could result in death, serious injury, or property damage. (000231a) WARNING Crushing hazard. Verify unit is properly secured and on level ground.
Operation 3. See Figure 3-14 for locations of the central lift point (A) and forklift pockets (B). • Attach any slings, chains or hooks directly to the central lift point. • Use the forklift pockets with care. Lift only from the side. Avoid approaching the unit at an angle, as this can permanently damage the forklift pockets, tires, or cabinet. Verify any obstructions are clear of the forklift tines before lifting. A B 006430 Figure 3-14.
Operation 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 3-15. Use the tie-down points (A) as shown. A 004438 Figure 3-15.
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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, etc.) 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 Item Daily Check engine oil level Check engine coolant level Check fuel level Drain water from fuel filters Check air cleaner dust valve restriction indicator gauges Inspect engine compartment Check tire pressure Service fire extinguisher Every 500 Every Hr/12 Mo 1,500 Hr Inspect wheel bearings d filter a, b Check open crankcase vent (OCV) system Replace fuel filter elements Check automatic belt tensioner and belt wea
Maintenance Engine Break-In Requirements 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. (000108) 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.
Maintenance DEF Tank Cleaning Proceed as follows to clean the DEF tank: 1. Drain DEF tank into a suitable container. See Disposal of DEF. 2. Flush DEF tank with distilled water, and fill with new or good DEF. Top-Wind Models • Apply a lightweight oil to the screw stem. Oil Grease Grease Disposal of DEF Large amounts of DEF should be contained. If large spills occur, contact local environmental authorities for assistance with clean up.
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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 Causes Solution Low fuel level shutdown Low fuel level Check fuel level on controller.
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Section 6: Wiring Diagrams Wiring Diagrams Owner’s Manual for Mobile Generator 51
V S REVISION: A PAGE 2 OF 12 BK/WT BK/WT BK/WT 27 26 25 28 29 30 31 1 5 4 194 RD/VI 3 150 GY/OR TO MHCRC-8 SEE PAGE 4 2 5 4 3 6 6 111 106 BK/WT 104 GY 51 GY 30 RD/VI 36 GY/BK 35 BK/WT 34 RD/BK 208 BK/WT 48 BK/WT 47 WT/VI (OPTIONAL) 13 13 91 (OPTIONAL) 107 BK/WT (OPTIONAL) 12 12 109 11 11 108 GY 10 10 107 9 9 8 8 106 105 GY 7 7 92 OR/BK (OPTIONAL) (OPTIONAL) 100 RD/VI 207 BK/WT TO BATT (-) 206 BK/WT TO BATT (-) TO 12V BATT 140 29 96 BK SHL
Wiring Diagrams GROUP G WIRING DIAGRAM FOR VOLTAGE REGULATION AUTOMATIC VOLTAGE REGULATOR (PM600) PMG NOT AVAILABLE AUTOMATIC VOLTAGE REGULATOR (PM600) PMG AVAILABLE 10 BN/WT 11 BN 8 NOT USED 18 NOT USED 9 9 NOT USED 9 BN/WT BN/WT 12 BK 13 RD 14 BN 600V 5A 12 BK 13 RD 16 5 7 17 8 WT BK 8 WT POTENTIOMETER POTENTIOMETER 133 BN/WT 132 BN 133 NOT USED 15 BN/WT 600V 5A 5 133 BN/WT 132 BN 17 NOT USED NOT USED BN/WT 16 NOT USED 14 BN 600V 5A 3 16 600V 5A 15 BN/WT 600V 5A 1
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Part No. A0000393893 Rev. A 05/18/2020 ©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.
