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Table of Contents
Related Manuals for Generac Power Systems MDG25IF4
Summary of Contents for Generac Power Systems MDG25IF4
- Page 1 Owner’s Manual Diesel Generator MDG25IF4 008730 For technical assistance contact: www.generacmobileproducts.com Technical Support 1-800-926-9768 Register your Generac product at: WWW.GENERAC.COM 1-888-GENERAC (1-888-436-3722) SAVE THIS MANUAL FOR FUTURE REFERENCE...
- Page 2 • 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. (000394) Owner’s Manual for MDG25IF4...
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Page 3: Table Of Contents
Alarms Tab ..............21 Section 4: Maintenance Input/Output Tab ............21 Emissions Information ..........35 Scheduler Tab ............22 Maintenance ...............35 Status Tab ..............22 Daily Walk Around Inspection ........35 Generator Monitoring ..........22 Belt Tensioners ............35 Engine Monitoring .............22 General Maintenance ..........35 Owner’s Manual for MDG25IF4... - Page 4 Wiring Diagram - Trailer Lights ........ 46 Wiring Diagram - Brake Wiring ......... 47 Wiring Diagram - 12V Battery Charger ....48 Wiring Diagram - Power Zone Low Oil Level (If Equipped) ............... 48 Service Log ..............49 Owner’s Manual for MDG25IF4...
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Page 5: Section 1: Introduction And Safety
To locate a GMP ASD, go to: this manual. www.generacmobileproducts.com/parts-service/ These safety alerts cannot eliminate the hazards that they find-service indicate. Common sense and strict compliance with the special instructions while performing the action or service are essential to preventing accidents. Owner’s Manual for MDG25IF4... -
Page 6: General Hazards
(000235) WARNING CAUTION 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) Owner’s Manual for MDG25IF4... -
Page 7: Electrical Hazards
Failure to do so could Risk of Fire. Unit must be positioned in a result in death or serious injury. (000238) manner that prevents combustible material accumulation underneath. Failure to do so could result in death or serious injury. (000147) Owner’s Manual for MDG25IF4... -
Page 8: Battery Hazards
• Loss of electrical output. • Equipment connected to the unit overheats. • Sparking occurs. • Engine misfires or there is excessive engine/ generator vibration. • Protective covers are loose or missing. • Ambient air temperature is above 120°F (49°C). Owner’s Manual for MDG25IF4... -
Page 9: Operating Safety
Before towing the trailer, verify the weight of the trailer is equal across all tires. On trailers with adjustable height hitches, adjust the angle of the trailer tongue to keep the trailer as level as possible. Owner’s Manual for MDG25IF4... -
Page 10: Safety And Operating Decals
Do not Open Door with Engine Running Terminal Connections (Voltage Selector Switch) CAN Lock Connectors Connection Terminal Lugs Remote Start Terminal Connections Circuit Breaker Electrical Backfeed Danger Operating Instructions Read and Understand Owner’s Manual Buttons Below Controller Neutral Neutral Bonded to Frame Owner’s Manual for MDG25IF4... - Page 11 Introduction and Safety 007607 Figure 1-1. Exterior Decals Owner’s Manual for MDG25IF4...
- Page 12 Introduction and Safety 007608 Figure 1-2. Interior Decals Owner’s Manual for MDG25IF4...
- Page 13 Introduction and Safety NEUTRAL (L0) BONDED TO FRAME NULLLEITER (L0) AM RAHMEN ANGESCHLOSSEN NEUTRO (L0) CONECTADO AL BASTIDOR POSITION NEUTRE (L0) LORSQUE FIXÉ AU CADRE 10000023204 007609 Figure 1-3. Control Panel Decals Owner’s Manual for MDG25IF4...
- Page 14 Introduction and Safety This page intentionally left blank. Owner’s Manual for MDG25IF4...
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Page 15: Section 2: General Information Specifications
(kg) 2,246 (1,018) Operating weight—trailer mounted lb (kg) 2,642 (1,198) Capacities Usable fuel gal (L) 48 (181) Coolant system gal (L) 4.4 (16.7) qts (L) 11 (10.4) Maximum run time hours AC Distribution Circuit breaker size Owner’s Manual for MDG25IF4... -
Page 16: Unit Dimensions
Specifications are subject to change without notice. Refer to the product specification sheet for complete list. Unit Dimensions 008731 Figure 2-1. Unit Dimensions Skid Mounted 35 in (0.89 m) 48 in (1.22 m) 70 in (1.78 m) Trailer Mounted 53 in (1.35 m) 65 in (1.65 m) 129 in (3.28 m) Owner’s Manual for MDG25IF4... -
Page 17: Component Locations
Figure 2-2. Component Locations Central Lift Point Alternator Fuel Fill Manual Holder Air Filter Coolant Overflow Container Generator (located behind air filter) Oil Drain Battery Coolant Drain Primary Fuel Filter M Control Panel Secondary Fuel Filter Fork Pockets Owner’s Manual for MDG25IF4... -
Page 18: Control Panel
General Information Control Panel 007612 Figure 2-3. Control Panel (rear of unit) Voltage Selector Switch Option Emergency Stop Button Option ® Run/Idle Switch PowerZone Controller Power Switch Fuel Transfer Pump Switch Owner’s Manual for MDG25IF4... - Page 19 Control Panel Lights (3) Ground Connection Lug 50A Circuit Breakers (2) Connection Lugs Service Lights Switch Remote Start Terminal Block 20A Circuit Breakers (2) Lug Door Safety Switch 120V GFCI Receptacles (2) 120V/240V Twist-Lock Receptacles (2) Owner’s Manual for MDG25IF4...
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Page 20: Unit And Serial Number Locations
Table 2-2. Altitude and Temperature Limitations Maximum Altitude Maximum Air Model Prime Standby Temperature Power Power 10,000 ft 4500 ft 111 °F MDG25 (3048 m) (1371 m) (44 °C) Owner’s Manual for MDG25IF4... -
Page 21: Powerzone® Controller
Fuel Transfer Pump Switch Voltage Adjust Button Engine Speed Switch Generator Button Navigation Buttons Engine Button Engine START Button Home Button Engine STOP Button Controller Power Switch AUTO or MANUAL Mode Button M N/A Alarm Mute Button Owner’s Manual for MDG25IF4... -
Page 22: Controller Features And Functions
Voltage Adjust Button (red text), a scheduled maintenance task, along with the Press to display the Voltage Adjust Screen. description of the maintenance procedure, and the action that will take place when the timer trips the alarm. Owner’s Manual for MDG25IF4... - Page 23 (kW). This screen also displays under-voltage or over-voltage conditions using the on- the generator winding configuration set by the voltage screen instructions. This feature replaces a traditional selector switch in the lower right corner. potentiometer. Owner’s Manual for MDG25IF4...
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Page 24: Maintenance Screens
480V/277V 3-Phase kVAr kVAh 0.00 kVArh kVAr 002790 Figure 2-11. Generator Summary Screen Volt Volt Volt Freq L1-L2 L2-L3 L3-L1 Volt Volt kVAr L1-L2 L2-L3 L3-L1 Engine Generator Alarms Schedule Status 007617 Figure 2-13. Generator Tab Screen Owner’s Manual for MDG25IF4... -
Page 25: Alarms Tab
The most recent events are listed first. All indexed events include the date and time of the event, and hours of runtime on the engine when it occurred, along with the event name or alarm type and details. Owner’s Manual for MDG25IF4... -
Page 26: Scheduler Tab
- DSR - DCD Engine Generator Alarms Schedule Status 002797 Figure 2-18. Status Tab Screen Generator Monitoring Generator information is displayed on both the generator button screen and generator tab within the Maintenance Screens. See Generator Tab. Owner’s Manual for MDG25IF4... -
Page 27: Section 3: Operation
Check engine exhaust system for loose or rusted Press the AUTO or MANUAL mode ( ) button to components. enter MANUAL mode. Verify the radiator and surrounding shroud are clear of debris. Verify all covers are in place and secure. Owner’s Manual for MDG25IF4... -
Page 28: Auto (Remote) Starting The Unit
The frequency should read start when AUTO mode is entered. Attach the switch approximately 60 Hz with no loads connected to leads to the two unused terminals (A) on the unit’s remote start terminal block. Owner’s Manual for MDG25IF4... -
Page 29: Wet Stacking
Synthetic oils have improved flow at low temperatures. The oil pan heater, battery heater and fuel filter heater (if equipped) are activated with a thermostat and will turn on and off as needed. The coolant heater is powered by a Owner’s Manual for MDG25IF4... -
Page 30: Using A Booster Battery Or Charger (If Equipped)
Failure to do so will result in death, serious injury, and equipment damage. (000237) DANGER Electrocution. Do not disable or modify the connection box door safety switch. Doing so will result in death or serious injury. (000157) Owner’s Manual for MDG25IF4... -
Page 31: Generator Cam Lock Connections (If Equipped)
Secure the standby power source. connection by rotating the plug a 1/2 turn to the right. Black Blue N (Neutral) White G (Ground) Green 007619 007618 Figure 3-8. Cam Lock Connections Figure 3-7. Generator Connection Lugs Owner’s Manual for MDG25IF4... -
Page 32: Using The Voltage Selector Switch
002803 NOTE: The version is also displayed in the top left Figure 3-9. Voltage Adjust Screen corner of the Configuration menu. See Accessing the Configuration Menu. 1. With the unit running, press Owner’s Manual for MDG25IF4... -
Page 33: Changing Back To 208V Configuration
(Parallel Low Wye) Configuration, changing the pre- Verify any problems that cause the main circuit breaker to alarm trip to 132V and the alarm trip to 134V. trip are corrected before returning the switch to ON (I). Owner’s Manual for MDG25IF4... -
Page 34: Transfer Switch
for five seconds. To cancel (utility) to the emergency power source (generator) when any changes and return to the maintenance normal voltage falls below a prescribed level. The screen, press and hold O for five seconds. Owner’s Manual for MDG25IF4... -
Page 35: Set The Controller Clock
NOTE: If setting up a daily scheduled run, select Weekly Run Mode, then set start time and duration for each day (seven schedule entries total). This will repeat the seven day schedule as long as the unit is in AUTO mode. Owner’s Manual for MDG25IF4... -
Page 36: Emergency Stop Switch
Second pass tighten to 50–60 ft-lbs (67–81 Nm). switch to turn the ECU OFF. If the unit needs to be shut down immediately, use the emergency stop switch. See Third pass tighten to 90–120 ft-lbs (122–162 Nm). Emergency Stop Switch. Owner’s Manual for MDG25IF4... -
Page 37: Lifting The Unit
For approximate weights, see Specifications. 2. Close and lock all hoods and doors. IMPORTANT NOTE: Always remain aware of people and objects around the work site when moving or lifting the unit. Owner’s Manual for MDG25IF4... - Page 38 Operation This page intentionally left blank. Owner’s Manual for MDG25IF4...
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Page 39: Section 4: Maintenance
Units with an automatic belt tensioner must be ADD markings on the overflow jug. inspected according to the manufacturer’s specifications. – When engine is stopped and completely cool, coolant may be added directly to the coolant overflow container. Owner’s Manual for MDG25IF4... -
Page 40: Engine Oil Recommendations
• Besco S – 3: CD premature equipment failure. Maintenance records may be required to complete a warranty request. • Besco Multi Z: CD IMPORTANT NOTE: Refer to the engine operator’s manual for additional maintenance information. Owner’s Manual for MDG25IF4... -
Page 41: Engine Break-In Requirements
For 2. Press ▲, ►, ▼, or ◄ to enter the maintenance more information on regular maintenance intervals, refer screens. Basic Maintenance Schedule. Owner’s Manual for MDG25IF4... -
Page 42: Checking Generator Drive Plate Torque
The minimum recommended lubrication is every 12 caster wheel must also be lubricated with the same months or 12,000 miles (19,312 km). More frequent lightweight oil. lubrication may be required under extremely dusty or damp operating conditions. Owner’s Manual for MDG25IF4... -
Page 43: Section 5: Troubleshooting
Disconnect all loads and restart unit. Read frequency (Hz) in the Overspeed or LCD window on controller. Frequency should read 60 Hz. Frequency setting incorrect Underspeed Shutdown If frequency is above 60 Hz, engine speed will need to be adjusted. Contact Isuzu to adjust speed. Owner’s Manual for MDG25IF4... - Page 44 Troubleshooting This page intentionally left blank. Owner’s Manual for MDG25IF4...
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Page 45: Section 6: Wiring Diagrams And Service Log
Wiring Diagrams and Service Log Section 6: Wiring Diagrams and Service Log Wiring Diagram - 3 Position AC Box Owner’s Manual for MDG25IF4... -
Page 46: Wiring Diagram - 4 Position Ac Box
Wiring Diagrams and Service Log Wiring Diagram - 4 Position AC Box Owner’s Manual for MDG25IF4... -
Page 47: Wiring Diagram - Receptacles
Wiring Diagrams and Service Log Wiring Diagram - Receptacles Wiring Diagram - Engine Heater Owner’s Manual for MDG25IF4... -
Page 48: Wiring Diagram - Wiring Buck (If Equipped)
Wiring Diagrams and Service Log Wiring Diagram - Wiring Buck (If Equipped) Wiring Diagram - Power Zone PMG Owner’s Manual for MDG25IF4... -
Page 49: Wiring Diagram - Power Zone Control Box
Wiring Diagrams and Service Log Wiring Diagram - Power Zone Control Box Owner’s Manual for MDG25IF4... -
Page 50: Wiring Diagram - Trailer Lights
Wiring Diagrams and Service Log Wiring Diagram - Trailer Lights Owner’s Manual for MDG25IF4... -
Page 51: Wiring Diagram - Brake Wiring
Wiring Diagrams and Service Log Wiring Diagram - Brake Wiring Owner’s Manual for MDG25IF4... -
Page 52: Wiring Diagram - 12V Battery Charger
Wiring Diagrams and Service Log Wiring Diagram - 12V Battery Charger Wiring Diagram - Power Zone Low Oil Level (If Equipped) Owner’s Manual for MDG25IF4... -
Page 53: Service Log
Service Log OIL GRADE: _____________________________________ BRAND: __________________________________ COOLANT MIXTURE: _____________________________ BRAND: __________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ Hours to Coolant Hours to Coolant Date Oil Level Date Oil Level Service Level Service Level Owner’s Manual for MDG25IF4... - Page 54 Wiring Diagrams and Service Log This page intentionally left blank. Owner’s Manual for MDG25IF4...
- Page 56 Part No. 10000024701 Rev. A 06/07/2018 ©2018 Generac Mobile Products, LLC All rights reserved. Specifications are subject to change without notice. Generac Mobile Products, LLC No reproduction allowed in any form without prior written 215 Power Drive, Berlin, WI 54923 consent from Generac Mobile Products, LLC.