Owner’s Manual For Diesel Generator MDG25IF4 008730 For technical assistance contact: www.generacmobileproducts.com Technical Support 1-800-926-9768 Register your Generac product at: WWW.GENERAC.
Use this page to record important information about your Mobile Generator Unit Model Number Unit Serial Number Engine Model Number Engine Serial Number Generator Model Number Generator Serial Number 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 Introduction ..................................................................1 Read This Manual Thoroughly ....................................1 PowerZone Controller Information Displays, Functions, and Reset .................................................22 Voltage Selector Switch ............................................22 How to Obtain Service .................................................1 Safety Rules .....................................
Engine Oil Recommendations .................................. 36 Recommended Oil Types ......................................... 36 Coolant Recommendation ........................................ 36 Basic Maintenance Schedule ................................... 36 Engine Break-In Requirements ................................ 37 Resetting Maintenance Alarms ................................ 37 Checking Generator Drive Plate Torque ................. 38 Jack Maintenance .........................................
Introduction and Safety Section 1: Introduction and Safety Introduction Thank you for purchasing a Generac Mobile Products LLC product. This unit has been designed to provide high performance, efficient operation, and years of use when maintained properly. The information in this manual is accurate based on products produced at the time of publication. The manufacturer reserves the right to make technical updates, corrections, and product revisions at any time without notice.
Introduction and Safety General Hazards 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) DANGER Asphyxiation. Do not operate unit without a properly functioning exhaust system. Doing so will result in death or serious injury. (000340) WARNING Loss of life. This product is not intended to be used in a critical life support application.
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 Personal Injury.
Introduction and Safety Battery Hazards Fuel Hazards DANGER DANGER Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury. (000188) 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 This unit features numerous safety and operating decals. These decals provide important operating instructions and warn of dangers and hazards. The following diagrams illustrate decal locations and descriptions. Replace any missing or hard-to-read decals and use care when washing or cleaning the unit. Decal part numbers can be found in the parts manual at www.generacmobileproducts.com. Table 1-1.
Introduction and Safety 1 1 11 2 3 10 4 9 2 8 5 6 2 2 7 007607 Figure 1-1.
Introduction and Safety 12 11 13 14 13 15 12 16 17 007608 Figure 1-2.
Introduction and Safety 29 19 28 20 27 21 26 25 22 24 NEUTRAL (L0) BONDED TO FRAME NULLLEITER (L0) AM RAHMEN ANGESCHLOSSEN 31 NEUTRO (L0) CONECTADO AL BASTIDOR POSITION NEUTRE (L0) LORSQUE FIXÉ AU CADRE 10000023204 23 23 23 30 18 007609 Figure 1-3.
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General Information Section 2: General Information Specifications Description Units MDG25DF4 Make — Isuzu® Model — 4LE2T EPA Tier — Tier 4 Final hp (kW) 33.5 (25) rpm 1800 Fuel consumption—100%: Standby / Prime gph (Lph) 2.3 (8.6) / 2.0 (7.4) Fuel consumption—75%: Standby / Prime gph (Lph) 1.7 (6.5) / 1.6 (6.1) Fuel consumption—50%: Standby / Prime gph (Lph) 1.2 (4.4) / 1.1 (4.
General Information Description Units MDG25DF4 Specifications are subject to change without notice. Refer to the product specification sheet for complete list. Unit Dimensions B A C B C A 008731 Figure 2-1. Unit Dimensions 12 A B C Skid Mounted 35 in (0.89 m) 48 in (1.22 m) 70 in (1.78 m) Trailer Mounted 53 in (1.35 m) 65 in (1.65 m) 129 in (3.
General Information Component Locations A B C D E F G H I J K N L M 008734 Figure 2-2.
General Information Control Panel A H G B F E D C 007612 Figure 2-3.
General Information A C B D E F L K J G H I 007613 Figure 2-4.
General Information Unit and Serial Number Locations See Figure 2-5 to locate the unit ID tag (A) and vehicle identification number (VIN) tag (B). Important information such as the unit model number, serial number, VIN, and tire loading information are listed on these tags. Record the information from these tags in the event the tags are lost or damaged. This information may be needed when ordering parts or requesting assistance. B A 007614 Figure 2-5.
General Information PowerZone® Controller The PowerZone controller is an auto start controller that monitors the unit and indicates operational status and fault conditions. The controller can be programmed to automatically start or stop based on time schedule, fault condition, or load demand. The controller constantly monitors vital generator and engine functions for a number of preprogrammed alarm and fault conditions.
General Information Controller Features and Functions These buttons are used to enter the various operator screens from any other screen. The operator screens consist of four screens: Home ( ), Engine ( ), Generator Button Press to display the Generator Screen. Engine Button Press to display the Engine Screen. Generator ( GEN ), and Voltage Adjust ( + V - ). See Operator Screens. Home Button Fuel Transfer Pump Switch Controller Power Switch Used to allow fuel into the engine.
General Information Manual Mode Manual Mode 40 60 20 190 80 210 170 20 230 30 10 40 30 100 0 GEN 150 250 50.9 PSI Oil press. 0 50 13.8 V Battery GEN 10 0 0 3 2 5 Maintenance Alarm Hours 1 174 To Service 2 174 To Service 3 174 To Service 1 5 Hrs 263 13 38 60 Freq 70 0 Volt 350 0 Amp 50 +V Volt Description Oil Maintenance Fuel Maintenance Air Maintenance 25 88 50 214 °F Coolant Temp.
General Information Engine Tab The engine tab contains maintenance and instrumentation data gathered from the engine. Above the engine analog meters is a row of alarm icons. Each icon can be one of three colors: gray (inactive), yellow (warning), or red (shutdown). The alarm icons from left to right are: water in fuel, emission filter, engine air inlet temperature, charge alternator, oil pressure, fuel level, battery voltage, coolant temperature, and ECU lamp.
General Information Alarms Tab The alarms tab displays warnings, electrical trip, shutdown alarms, and any engine diagnostic trouble codes (DTC) that are occurring or have occurred. The first page displays the alarms that are currently active and organizes them by alarm type. SITE GENSET 7741 \ 7740 10:00:00 Total 0.0 % 0.0 % kW kVAr Warning Shutdown Return Delay 10:00:00 Total 0.0 Hz 0.0 % 0.0 % kW kVAr GEN +V - Generator 0.0 kWh+ 0.0 kW 0.0 kVA 0.0 kVAr 0.00 pf 0.0 Hz 7741 \ 7740 GENS
General Information Scheduler Tab Engine Monitoring The scheduler tab shows the current configuration and status of the scheduler, located below the generator summary. The maintenance configuration status and time remaining until an alarm, electrical trip, or shutdown will be displayed at the bottom of the screen. The lamp(s) to the left shows the configuration status of the maintenance alarm, not the alarm condition.
Operation 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 generator, depending on the type of engine governing used. Stop Mode Time to Empty 15 hr 0.0 kW 80 110 90 100 70 60 GEN 50 40 +V - 30 20 10 0 % Full 3 PHASE Volts 3/4 0 1/2 1/4 Amps 0 Empty 74 % 002805 Figure 3-2. Home Screen NOTE: The controller can be started from any screen when it is in MANUAL mode. 4.
Operation shore power 120V electrical connection that can be found in the convenience receptacle. The crankcase ventilation heater is powered by the generator and will stay on when the engine is operating in cold weather conditions. A 002806 Figure 3-3. Remote Start Terminal Block Wet Stacking The unit is powered by a diesel engine. Diesel engines are susceptible to wet stacking if lightly loaded.
Operation Using a Booster Battery or Charger (if equipped) Parallel: • Amps = Twice as a single battery • Volts = Same as single battery 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. (000137a) WARNING (000138a) 004508 CAUTION Figure 3-6. Parallel Equipment damage. Do not make battery connections in reverse.
Operation 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) WARNING Electric shock. Only a trained and licensed electrician should perform wiring and connections to unit. Failure to follow proper installation requirements could result in death, serious injury, and equipment or property damage.
Operation 2. Press . The voltages displayed will flash. DANGER 3. Use ▲ and ▼ to adjust the voltage. Electrocution. Do not disable or modify the connection box door safety switch. Doing so will result in death or serious injury. (000157) A ground connection is located on the far right of the cam lock panel. The unit must be connected to a good earthen ground for proper operating safety. The generator neutral is bonded to ground when it is shipped from the factory.
Operation After verifying the unit has V4 or higher of the PowerZone controller application, proceed as follows to achieve 240V while in the 208V configuration: 4. Starting in any of the operator screens, press ▲, ►, ▼, or ◄ to enter the maintenance screens. 5. Press and O simultaneously. The next screen will display the configuration menu. 6. Press ▼ to move the cursor (blue highlighted text) down to Config Selection. 7. Press ► to highlight Config to Edit.
Operation NOTE: The main circuit breaker only interrupts power to the connection lugs and the optional cam lock receptacles. The customer convenience receptacles have power even if the main circuit breaker is OFF (O). Use the individual circuit breakers located near each receptacle to disconnect power to these receptacles. transfer switch automatically returns the load back to the normal source when power is restored back to operating levels. Transfer Switch A B F C E D DANGER Loss of life.
Operation Set the Controller Clock Setting Up a Daily Scheduled Run The schedule runs based on the time set in the controller clock. Proceed as follows to set the controller clock before setting the schedule: 1. Navigate to the maintenance group and press ► to access it. 2. Press ► to select the time section. 3. Set the time and date to the correct local time. 1. Enable the scheduler. 2. Set RUN mode to Weekly. 3. Set load to preferred method. 4.
Operation Emergency Stop Switch Towing the Unit WARNING CAUTION Equipment Damage. The emergency stop switch is not to be used to power down the unit under normal operating circumstances. Doing so will result in equipment damage. (000246) See Figure 2-3. The unit is equipped with one emergency stop switch. The red button is clearly labeled EMERGENCY STOP. The switch can be accessed and activated with all doors closed and locked.
Operation 3. See Figure 3-12 for location of the central lift point (A) and forklift pockets (B). 4. Attach any slings, chains or hooks directly to the central lift point. 1 4 3 2 A 5 007620 Figure 3-11. Lug Sequence A 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) NOTE: Maximum recommended speed for highway towing is 45 mph (72 km/h).
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Maintenance 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. – Normal operating level is in the cross-hatch pattern between the FULL and ADD markings on the dipstick. – Add oil only if the oil level is below the ADD mark on the bottom of the cross-hatch pattern on the dipstick.
Maintenance Table 4-1. Basic Maintenance Schedule Item Check engine oil level Check engine coolant level Check fuel level Drain fuel filter Check tire pressure Check all electrical connections Clean battery Check fan belt tension (replace if necessary) Inspect radiator fins for debris; clean as required Pre-heating condition check Check engine starting and noise conditions Check exhaust smoke condition Perform Daily Walk Around Inspection First 50 Hrs. Daily (Breakin Period) Every 500 Hrs.
Maintenance 3. Press and O simultaneously. The next screen displays the Configuration menu. 4. Press to move the cursor (blue highlighted text) down to the maintenance group. 5. Press ► to access the sections. Press to highlight the maintenance section. Top-Wind Models • Apply a lightweight oil to the screw stem. Oil Grease 6. Press ► to access the parameters and highlight the maintenance alarm that needs to be reset. Grease 7. Press to select the editable parameters.
Troubleshooting Section 5: Troubleshooting General Troubleshooting This information is intended to be a check or verification for simple causes that can be located and fixed. It does not cover all types of problems. See the engine operator’s manual for additional troubleshooting information. Procedures that require in-depth knowledge or skills should be performed by a GMP ASD.
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Wiring Diagrams and Service Log Section 6: Wiring Diagrams and Service Log Wiring Diagram - 3 Position AC Box Owner’s Manual for MDG25IF4 41
Wiring Diagrams and Service Log Wiring Diagram - 4 Position AC Box 42 Owner’s Manual for MDG25IF4
Wiring Diagrams and Service Log Wiring Diagram - Receptacles Wiring Diagram - Engine Heater Owner’s Manual for MDG25IF4 43
Wiring Diagrams and Service Log Wiring Diagram - Wiring Buck (If Equipped) Wiring Diagram - Power Zone PMG 44 Owner’s Manual for MDG25IF4
Wiring Diagrams and Service Log Wiring Diagram - Power Zone Control Box Owner’s Manual for MDG25IF4 45
Wiring Diagrams and Service Log Wiring Diagram - Trailer Lights 46 Owner’s Manual for MDG25IF4
Wiring Diagrams and Service Log Wiring Diagram - Brake Wiring Owner’s Manual for MDG25IF4 47
Wiring Diagrams and Service Log Wiring Diagram - 12V Battery Charger Wiring Diagram - Power Zone Low Oil Level (If Equipped) 48 Owner’s Manual for MDG25IF4
Wiring Diagrams and Service Log Service Log OIL GRADE: _____________________________________ BRAND: __________________________________ COOLANT MIXTURE: _____________________________ BRAND: __________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ _____________
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Part No. 10000024701 Rev. A 06/07/2018 ©2018 Generac Mobile Products, LLC All rights reserved. Specifications are subject to change without notice. No reproduction allowed in any form without prior written consent from Generac Mobile Products, LLC. Generac Mobile Products, LLC 215 Power Drive, Berlin, WI 54923 GeneracMobileProducts.
