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Summary of Contents for Generac Power Systems MAGNUM MMG25IF4
- Page 1 DIESEL GENERATOR MMG25IF4 • MMG35DF4 MMG45IF4 • MMG55DF4 With Controller 01306 OPERATING MANUAL Parts manuals available online at www.generacmobile.com 36949 B 02/16...
- Page 2 WARNING CALIFORNIA PROPOSITION 65 WARNING: Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. (000004) WARNING CALIFORNIA PROPOSITION 65 WARNING: This product contains or emits chemicals known to the state of California to cause cancer, birth defects, and other reproductive harm.
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Page 3: Introduction
Introduction This manual provides information and procedures to safely operate and maintain the Generac Mobile Products unit. For your own safety and protection from physical injury, carefully read, understand, and observe the safety instructions described in this manual. Keep a copy of this manual with the unit at all times. Additional copies are available from Generac Mobile Products, or can be found at www.generacmobile.com.The information contained in this manual was based on machines in production at the time of publication. - Page 4 This Page Intentionally Left Blank...
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Page 5: Table Of Contents
Table of Contents Introduction ..........................iii Section 1 - Safety Safety Notes ............................1 Operating Safety..........................1 Engine Safety ............................. 2 Service Safety ............................ 2 Towing Safety............................. 3 Reporting Trailer Safety Defects ......................3 Safety Symbol Summary ........................4 Section 2 - General Information Specifications ............................. - Page 6 Section 4 - Maintenance Emissions Information ........................37 Daily Walk Around Inspection......................37 General Maintenance ........................37 Basic Maintenance Schedule - Isuzu Engine ................... 39 Basic Maintenance Schedule - John Deere Engine ................. 40 Isuzu Engine Break-In Requirements....................41 John Deere Engine Break-In Requirements..................41 Resetting the Maintenance Alarms....................
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Page 7: Section 1 - Safety
Section 1 - Safety SAFETY NOTES This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. This manual contains DANGERS, WARNINGS, CAUTIONS, NOTICES and NOTES which must be followed to prevent the possibility of improper service, damage to the equipment, personal injury or death. -
Page 8: Engine Safety
Safety 1. Noticeable change in engine speed. 2. Loss of electrical output. 3. Equipment connected to the unit overheats. 4. Sparking occurs. 5. Engine misfires or there is excessive engine/generator vibration. 6. Protective covers are loose or missing. 7. If the ambient air temperature is above 120°F (49°C). ENGINE SAFETY Internal combustion engines present special hazards during operation and fueling. -
Page 9: Towing Safety
Safety • DO NOT start the unit under load. The circuit breakers must be in the OFF (O) position when starting the unit in Manual mode. The circuit breakers can be in the ON (I) position only when started in the Auto mode. -
Page 10: Safety Symbol Summary
Safety You can also obtain other information about motor vehicle safety from http://www.safercar.gov. SAFETY SYMBOL SUMMARY This equipment has been supplied with numerous safety and operating decals. These decals provide important operating instructions and warn of dangers and hazards. Replace any missing or hard-to-read decals and use care when washing or cleaning the unit. -
Page 11: Section 2 - General Information
Section 2 - General Information SPECIFICATIONS GENERAC MODEL MMG25IF4 Engine Make/Brand........................... Isuzu Model ............................ 4LE2TAGV-03 EPA Tier ..........................F4 Horsepower - prime hp (kW) ....................36.2 (27.0) Horsepower - standby hp (kW) .................... 40.2 (30.0) Operating Speed rpm ......................1800 Displacement in (L) ...................... - Page 12 General Information GENERAC MODEL MMG35DF4 Engine Make/Brand........................... John Deere Model ............................ 3029HFG03 EPA Tier ..........................F4 Horsepower - prime hp (kW) ....................44 (33) Horsepower - standby hp (kW) .................... 48 (36) Operating Speed rpm ......................1800 Displacement in (L) ......................177 (2.9) Cylinders - qty ........................
- Page 13 General Information GENERAC MODEL MMG45IF4 Engine Make/Brand........................... Isuzu Model ............................ 4LE2XAGV01 EPA Tier ..........................F4 Horsepower - prime hp (kW) ....................57 (42.8) Horsepower - standby hp (kW) .................... 63.7 (47.5) Operating Speed rpm ......................1800 Displacement in (L) ......................134 (2.2) Cylinders - qty ........................
- Page 14 General Information GENERAC MODEL MMG55DF4 Engine Make/Brand........................... John Deere Model ............................ 3029HFG03 EPA Tier ..........................F4 Horsepower - prime hp (kW) ....................67 (50) Horsepower - standby hp (kW) .................... 74 (55) Operating Speed rpm ......................1800 Displacement in (L) ......................177 (2.9) Cylinders - qty ........................
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Page 15: Unit Dimensions
General Information Unit Dimensions 01906 Figure 2-1. Unit Dimensions A (Width) B (Length) C (Height) MMG25IF4/35DF4/45IF4/55DF4 - 39 in. (.99 m) 95 in. (2.41 m) 65 in. (1.65 m) Skid Mounted MMG25IF4/35DF4/45IF4/55DF4 - 58 in. (1.45 m) 152 in. (3.81 m) 83 in. -
Page 16: Unit Serial Number Locations
UNIT ID Tag VIN Tag Manufactured by Generac Mobile Products, LLC., TIRE AND LOADING INFORMATION a subsidiary of Generac Power Systems, Inc. MANUFACTURED BY/FABRIQUE PAR: Generac Mobile Products LLC DATE: 00/0000... -
Page 17: Component Locations
General Information COMPONENT LOCATIONS 01880 Figure 2-3. Component Locations Engine exhaust Lug box panel access Radiator access panel Containment drain/fuel drain port Central lift point Receptacle panel Fuel fill Emergency stop Engine and battery access Control access panel Radiator drain port Breaker panel access Engine access 36949 B... -
Page 18: Control Panel
General Information CONTROL PANEL 01881 Figure 2-4. Control Panel (Rear of Unit) Voltage selector switch Engine idle switch 50/60 Hz switch (optional) Control power switch Fuel transfer pump switch (optional) Power Zone™ controller MMG25I-35D-45I-55DF4 Operating Manual 36949 B... - Page 19 General Information 01882 Figure 2-5. Control Panel (Right Side of Unit) Main circuit breaker Connection lugs (4) Control panel lights (3) Cam lock connection lugs (5) (optional) 50A circuit breakers (3) Connection for optional equipment inlet Service lights switch 120V/240V twist-lock receptacles (3) 20A circuit breakers (2) Connection for battery charger Lug door safety switch...
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Page 20: Power Zone™ Gen Controller
General Information POWER ZONE™ GEN CONTROLLER The Power Zone™ Gen 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. -
Page 21: Operator Screens
General Information Auto/Manual Mode The Auto/Manual Mode ( ) button is used to change the startup and shutdown modes of the unit. When pressed once, the unit enters Manual mode and when pressed and held for five seconds, the unit enters Auto mode. If in Auto mode, pressing once will return the unit to Manual mode. - Page 22 General Information Manual Mode Time to Empty 15 hr 100 110 Full 3 PHASE 106.9 kW Volts Amps Empty 00393 Figure 2-7. Home Screen Engine Screen The Engine screen displays the oil pressure, coolant temperature and battery voltage on three main gauges. Below the gauges is an hour gauge displaying the total run time on the engine.
- Page 23 General Information Generator Screen The Generator screen displays the average voltage frequency, volts and amps from the generator, as well as line- to-line voltage, and individual line-to-neutral voltage, amperage and power (kW). This screen also displays the generator winding configuration set by the voltage selector switch in the lower right corner. Manual Mode Volt Freq...
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Page 24: Maintenance Screens
General Information Maintenance Screens All of the data inputs from the engine, generator, inputs/outputs, schedule and Power Zone™ controller are visible on the maintenance screens. The information displayed on the maintenance screens can be used to identify, diagnose and troubleshoot unit shutdown conditions and poor unit performance. - Page 25 General Information SITE GENSET 7741 \ 7740 480V/277V 3-Phase 07:10 Return Delay 10:00:00 Total Generator kWh+ kVAr kVAh 0.00 kVAr kVArh Volt Volt Volt Freq L1-L2 L2-L3 L3-L1 Volt Volt kVAr L1-L2 L2-L3 L3-L1 Engine Generator Alarms Schedule Status 00399 Figure 2-13.
- Page 26 General Information SITE GENSET 7741 \ 7740 07:10 480V/277V 3-Phase Return Delay 10:00:00 Total Generator kWh+ kVAr kVAh 0.00 kVAr kVArh Index Date Time Event Details 01/01/1970 00:00:01 0:00 Shutdown This is an event index 1 02/06/1970 11:45:55 0:00 Shutdown This is an event index 2 Warning 01/01/1970...
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Page 27: Generator Monitoring
General Information SITE GENSET 7741 \ 7740 480V/277V 3-Phase 07:10 Return Delay 10:00:00 Total Generator kWh+ kVAr kVAh 0.00 kVAr kVArh Scheduler Enabled to run Reserved Reserved Event Week Start Stop Duration Event Week Start Stop Duration Monday 00:00 00:00 0:00 Monday 00:00... -
Page 28: Belt Tensioners
General Information BELT TENSIONERS Isuzu™ engines use only manual belt tensioners. John Deere™ engines use manual and automatic belt tensioners. Adjust the belt using the manual tensioner according to the manufacturer’s specifications. The automatic tensioner cannot be adjusted or repaired and is designed to maintain proper tension over the life of the belt. Units with the automatic belt tensioner must be inspected according to manufacturer specifications. -
Page 29: Section 3 - Operation
Section 3 - Operation PRESTART CHECKLIST Before starting the unit, carefully read the prestart checklist. Verify all items are checked before starting the unit. This checklist applies to both manual and remote starting of the unit. Read and understand ALL safety sections at the beginning of this manual. ... -
Page 30: Auto (Remote) Starting Of The Unit
Operation When the software is loaded, the Home screen will be displayed and the controller will be in Stop mode as indicated at the top of the screen. Press the Auto/Manual Mode ( ) button to enter Manual mode. Stop Mode Time to Empty 15 hr 100 110... -
Page 31: Derating For Altitude
Operation and information on isolating the generator with a transfer switch if the unit is to be used as a standby power supply. Transfer Switch, then continue with the steps described below: 1. Perform a manual start of the unit to verify the engine is operating correctly. Remove the wires from the remote start terminal block to check the remote start circuit. -
Page 32: Fine Voltage Adjustment
Operation DANGER IMPROPER OR INCORRECT CONNECTIONS TO A BUILDING’S ELECTRICAL SYSTEM CAN CAUSE POTENTIALLY LETHAL VOLTAGES TO BACKFEED INTO UTILITY LINES. THIS MAY RESULT IN INJURY OR ELECTROCUTION TO UTILITY WORKERS NEARBY. VERIFY THE GENERATOR IS SUPPLYING POWER TO AN ISOLATED OBJECT OR BUILDING THAT IS NOT CONNECTED TO ANY UTILITY LINES. -
Page 33: Voltage Selector Switch
Operation VOLTAGE SELECTOR SWITCH The voltage selector switch mechanically changes the connections between the generator output leads and the connection lugs on the main control panel. Voltage ranges are selected by rotating the handle on the switch to the desired voltage. WARNING Electric Shock: Never change the voltage selector switch while the engine is running or the controller is on. -
Page 34: Voltage Regulation
Operation 120/240V 1-PHASE L1-L2 = L1-N = 120V 120/ 208V L2-L3 = L2-N = L3-L1 = 240V L3-N = 120V 120/ VOLTAGES AT RECEPTACLES 240V RECEPTACLE GFCI 120V GFCI w/Buck 120V Twist-locks 240V 120V Switch styles vary by model. 00087 Figure 3-6. -
Page 35: Main Circuit Breaker
Operation 120V GFCI 50A Circuit 20A Circuit Receptacles Breakers Breakers 125/250V Twist-Lock Receptacles 01034 Figure 3-7. Receptacle and Breaker Locations 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 RECEP- TACLES IS TURNED OFF BEFORE TURNING THE BREAKERS ON. -
Page 36: Exhaust Filter Cleaning Operations
Operation 1. Overload of the generator circuits to the connection lugs or the optional cam lock receptacles. The door covering the connection lugs or the optional cam lock receptacles is opened. If the emergency stop switch is activated. Verify problems that cause the main circuit breaker to trip are corrected before returning the switch to ON (I). The main circuit breaker interrupts power to the connection lugs and the optional cam lock receptacles only. -
Page 37: Enable Exhaust Filter Cleaning
Operation 1. Open the control door and locate the switch labeled “FORCE EXHAUST REGENERATION”. 2. Move and hold the switch into the position. Enable Exhaust Filter Cleaning If the environment no longer requires the function to be disabled and there are no alarms present on the DPF Status screen, the auto exhaust filter cleaning function should be enabled. -
Page 38: Auto Exercise Timer
Operation DANGER FAILURE TO ISOLATE THE GENERATOR FROM THE NORMAL POWER UTILITY CAN CAUSE POTENTIALLY LETHAL VOLTAGE TO BACKFEED INTO THE UTILITY LINES. THIS MAY RESULT IN INJURY OR ELECTROCUTION OF UTILITY WORKERS NEARBY. MAKE SURE THE GENERATOR IS ISOLATED BY A TRANSFER SWITCH FROM ANY LOCAL UTILITY LINES. -
Page 39: Set The Schedule
Operation Set the Schedule 1. Access the Scheduler group by pressing the ► button. Note: The Scheduler group is made up of the Scheduler Options and Scheduler Setup sections. Each section can be accessed and exited using the ► and ◄ buttons. Access the Scheduler Options section. -
Page 40: Emergency Stop Switch
Operation Push (O). Pressing the red Engine Stop/Reset (O) button will result in the generator going into the shutdown cycle and starting a 15 second shutdown timer called stopping. If the unit does not shut down within 15 sec- onds, a stop fail alarm will be displayed on the LCD window. After the unit shuts down, move the Control Power switch to OFF (O). -
Page 41: Lifting The Unit
Operation Connect any trailer wiring to the tow vehicle. Check for proper operation of the directional and brake lights. Make sure the doors are properly latched. Check for proper inflation of the trailer tires. For maximum tire pressures, refer to Specifications. Check the wheel lugs. - Page 42 Operation This Page Intentionally Left Blank MMG25I-35D-45I-55DF4 Operating Manual 36949 B...
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Page 43: Section 4 - Maintenance
Section 4 - Maintenance EMISSIONS INFORMATION For emissions information, see the OEM engine manual. DAILY WALK AROUND INSPECTION Look for conditions that could hinder performance or safety, such as (but not limited to) oil/coolant/fuel leakage, blocked vents, loose/missing hardware, and electrical connections. Visually inspect the fan belt for cracks, fraying, stretching, and verify the belt is properly seated in the pulley grooves. - Page 44 Maintenance normal range. ○ WHEN ENGINE IS STOPPED AND COMPLETELY COOL, coolant may be added directly to the coolant overflow jug. • Check the oil level daily. Refer to the engine operator’s manual for the proper viscosity grade of oil, including special operating conditions such as a change in season or climate.
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Page 45: Basic Maintenance Schedule - Isuzu Engine
Maintenance BASIC MAINTENANCE SCHEDULE - ISUZU ENGINE See the original equipment manufacturer’s operating manual for a complete list of mainte- nance requirements. Failure to comply with the procedures as described in the engine operator manual will nullify the warranty, decrease performance and cause equipment damage or premature equipment failure. -
Page 46: Basic Maintenance Schedule - John Deere Engine
Maintenance BASIC MAINTENANCE SCHEDULE - JOHN DEERE ENGINE See the original equipment manufacturer’s operating manual for a complete list of mainte- nance requirements. Failure to comply with the procedures as described in the engine operator manual will nullify the warranty, decrease performance and cause equipment damage or premature equipment failure. -
Page 47: Isuzu Engine Break-In Requirements
Maintenance Replace primary air cleaner when dust valve restriction indicator gauge shows a vacuum of 25 in. H If not using John Deere Plus 50 II engine oil, the interval must be decreased to every 250 hours. ISUZU ENGINE BREAK-IN REQUIREMENTS Note: The EPA final Tier 4 Isuzu engines have an engine break-in duration that will prohibit the unit from providing rated standby power upon factory delivery. -
Page 48: Checking Generator Drive Plate Torque
Maintenance 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 () return to the parameters section. To save changes, press and hold () for five seconds. To discard changes made, press and hold (O) for five seconds. -
Page 49: Jack Maintenance
Maintenance Install generator fan guard. Connect battery. JACK MAINTENANCE The following procedures should be performed annually. Side-Wind Models • The internal gearing and bushings of the jack must be kept lubricated. Apply a small amount of automotive grease to the internal gearing by removing the jack cover, or if equipped, use a needle nose applicator or standard grease gun on the lubrication point found on the side of the jack near the crank. - Page 50 Maintenance This Page Intentionally Left Blank MMG25I-35D-45I-55DF4 Operating Manual 36949 B...
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Page 51: Section 5 - Troubleshooting
Section 5 - Troubleshooting TROUBLESHOOTING AUTOMATIC SHUTDOWN CONDITIONS WARNING Allow engine to cool before performing any troubleshooting procedures. Contacting the engine when it is hot will cause personal injury. Low Fuel Level Shutdown 1. Check fuel level on the Liquid Crystal Display (LCD) window. Verify the unit is sitting level to ensure an accurate reading. - Page 52 Troubleshooting This Page Intentionally Left Blank MMG25I-35D-45I-55DF4 Operating Manual 36949 B...
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Page 53: Section 6 - Wiring Diagrams
Section 6 - Wiring Diagrams AC WIRING - MMG25IF4, MMG45IF4 90580_ORG_10.14.14 36949 B MMG25I-35D-45I-55DF4 Operating Manual... -
Page 54: Ac Wiring - Mmg35Df4, Mmg55Df4
Wiring Diagrams AC WIRING - MMG35DF4, MMG55DF4 90632_ORG_01.14.15 MMG25I-35D-45I-55DF4 Operating Manual 36949 B... -
Page 55: Ac Wiring - 4 Pos. Voltage Selector Switch Option - Mmg25If4, Mmg45If4
Wiring Diagrams AC WIRING - 4 POS. VOLTAGE SELECTOR SWITCH OPTION - MMG25IF4, MMG45IF4 90581_ORG_10.14.14 36949 B MMG25I-35D-45I-55DF4 Operating Manual... -
Page 56: Ac Wiring - 4 Pos. Voltage Selector Switch Option - Mmg35Df4, Mmg55Df4
Wiring Diagrams AC WIRING - 4 POS. VOLTAGE SELECTOR SWITCH OPTION - MMG35DF4, MMG55DF4 90633_ORG_01.20.15 MMG25I-35D-45I-55DF4 Operating Manual 36949 B... -
Page 57: Ac Wiring Option - Standard Receptacles
Wiring Diagrams AC WIRING OPTION - STANDARD RECEPTACLES 3 POS BLK GND STUD BRKR BRKR BRKR 20 20 GFCI1 GFCI2 2 POS BLK GN/YL GN/YL GN/YL 90582_ORG_08.18.14 AC WIRING OPTION - ENGINE HEATER EDISON PLUG ENGINE HEATER 90594_ORG_10.29.14 36949 B MMG25I-35D-45I-55DF4 Operating Manual... -
Page 58: Ac Wiring Option - Buck Transformer
Wiring Diagrams AC WIRING OPTION - BUCK TRANSFORMER TO 120V TO 120V BREAKERS BREAKERS VOLTAGE RELAY VOLTAGE RELAY POWER POWER RELAY RELAY 3 POS BLK 3 POS BLK BUCK BUCK XFMR XFMR 90583_ORG_08.18.14 AC WIRING OPTION - PMG 1 2 3 4 5 6 7 REMOVE JUMPERS FOR PMG 90589_ORG_08.18.14 MMG25I-35D-45I-55DF4 Operating Manual... -
Page 59: Dc Wiring
Wiring Diagrams DC WIRING 90540_D_06.15.15 36949 B MMG25I-35D-45I-55DF4 Operating Manual... -
Page 60: Trailer Lights Wiring
Wiring Diagrams TRAILER LIGHTS WIRING TRAILER PLUG RIGHT AMBER MARKER LAMP LEFT AMBER MARKER LAMP RIGHT LEFT MARKER MARKER LAMP LAMP STOP-TURN SIGNAL STOP-TURN LAMP SIGNAL (RIGHT) LAMP (LEFT) LICENSE PLATE LAMP 90584_ORG_10.02.14 MMG25I-35D-45I-55DF4 Operating Manual 36949 B... -
Page 61: Wiring Harness - Electric Brake Option
Wiring Diagrams WIRING HARNESS - ELECTRIC BRAKE OPTION 90286_E_03.18.14 36949 B MMG25I-35D-45I-55DF4 Operating Manual... -
Page 62: Dc Wiring Option - 12V Battery Charger
Wiring Diagrams DC WIRING OPTION - 12V BATTERY CHARGER EDISON PLUG YEL/GRN 16/3 BATTERY CHARGER 12 V BATTERY 90593_ORG_10.29.14 DC WIRING OPTION - LOW OIL LEVEL LEVEL 90595_ORG_10.31.14 MMG25I-35D-45I-55DF4 Operating Manual 36949 B... -
Page 63: Section 7 - Options & Accessories
Section 7 - Options & Accessories GENERATOR CAM LOCK CONNECTIONS OPTION The unit may be equipped with cam lock connections, located below the connection lugs. These receptacles provide connection points for the attachment of external loads to the generator. A decal near the cam lock connections details the proper connections for selected voltages. -
Page 64: Viscous Fan Clutch Option
Options & Accessories VISCOUS FAN CLUTCH OPTION The viscous fan clutch option allows the engine cooling fan to engage at lower speeds and disengage at higher speeds, increasing cooling system efficiency. The cooling fan will engage at full speed when the coolant temperature rises. -
Page 65: 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... - Page 66 Notes ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________...
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