Generac Power Systems MDG25IF4 Owner's Manual
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Generac Power Systems MDG25IF4 Owner's Manual

Generac Power Systems MDG25IF4 Owner's Manual

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Owner's Manual
Diesel Generator
MDG25IF4
SN ____________ and higher
For technical assistance contact:
www.generacmobileproducts.com
Technical Support
1-800-926-9768
SAVE THIS MANUAL FOR FUTURE REFERENCE

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  • Page 1 Owner’s Manual Diesel Generator MDG25IF4 SN ____________ and higher For technical assistance contact: www.generacmobileproducts.com Technical Support 1-800-926-9768 SAVE THIS MANUAL FOR FUTURE REFERENCE...
  • Page 2 Use this page to record important information about your unit. Record the information found on your unit data label on this page. See unit serial number location (Unit Serial Unit Model No. Number Locations). The label plate is affixed to the inside partition, to the left of the control panel console.

  • Page 3: Table Of Contents

    Table of Contents Section 1: Introduction and Safety Low Idle Switch ............27 Cold Weather Operation ..........27 Introduction ..............1 Read This Manual Thoroughly ........1 Using a Booster Battery or Charger (if equipped) ..28 How to Obtain Service ..........1 Parallel: ..............28 Safety Rules ..............1 Generator Output Connections ........28 Safety Symbols and Meanings ........1...
  • Page 4 Section 5: Troubleshooting General Troubleshooting .......... 41 Section 6: Wiring Diagrams Controls ..............43 Control Box (1 of 2) ........... 44 Control Box (2 of 2) ........... 45 Generator Cabin (1 of 2) ........... 46 Generator Cabin (2 of 2) ..........47 Generator Box—VFLEX (If Equipped) .....

  • Page 5: Section 1: Introduction And Safety

    Section 1: Introduction and Safety Introduction Safety Rules Thank you for purchasing a Generac Mobile product. The manufacturer cannot anticipate every possible This unit been designed provide high circumstance that might involve a hazard. The warnings performance, efficient operation, and years of use when in this manual, and on tags and decals affixed to the unit maintained properly.

  • Page 6: General Hazards

    Introduction and Safety General Hazards WARNING DANGER Risk of injury. Do not operate or service this machine Asphyxiation. Running engines produce carbon if not fully alert. Fatigue can impair the ability to monoxide, a colorless, odorless, poisonous service this equipment and could result in death or gas.

  • Page 7: Electrical Hazards

    Introduction and Safety Electrical Hazards Lifting Hazards DANGER WARNING Electrocution. In the event of electrical accident, Personal injury. Failure to properly connect immediately shut power OFF. Use non-conductive lifting cables, chains, or straps could result in implements to free victim from live conductor. Apply death, serious injury, or property damage.

  • Page 8: Battery Hazards

    Introduction and Safety Battery Hazards Fuel Hazards DANGER DANGER Explosion and fire. Fuel and vapors are extremely Electrocution. Do not wear jewelry while flammable and explosive. No leakage of fuel is working on this equipment. Doing so will permitted. Keep fire and spark away. Failure to do result in death or serious injury.

  • Page 9: Operating Safety

    Introduction and Safety Operating Safety Reporting Trailer Safety Defects If you believe your trailer has a defect which could cause a crash or could cause injury or death, you should Positioning the Unit immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Generac WARNING Mobile.

  • Page 10: Safety And Operating Decals

    Introduction and Safety Safety and Operating Decals This unit features numerous safety and operating decals. Replace any missing or hard-to-read decals and use care These decals provide important operating instructions when washing or cleaning the unit. Decal part numbers and warn of dangers and hazards. The following found parts manual...
  • Page 11 Introduction and Safety Inside door on plexi-glass panel 007607 Figure 1-1. Exterior Decals Owner’s Manual for Mobile Generator...
  • Page 12 Introduction and Safety 10000022551 10000022644 SECONDARY FILTER PRIMARY FILTER Generator can automatically start which can cause serious injury. Disconnect battery before servicing. Der Generator kann automatisch anspringen und schwere Verletzungen Black verursachen. Vor der Instandsetzung die Batterieverbindungen lösen. El generador puede arrancar automáticamente, lo que puede causar graves lesiones.
  • Page 13 Introduction and Safety Control Panel CONTROLLER ENGINE POWER SPEED A0000705133 Backside of control panel access door Connection Panel NEUTRAL (L0) BONDED TO FRAME NULLLEITER (L0) AM RAHMEN ANGESCHLOSSEN NEUTRO (L0) CONECTADO AL BASTIDOR POSITION NEUTRE (L0) LORSQUE FIXÉ AU CADRE CAUTION 120V GFCI receptacles not for use when generator is...
  • Page 14 Introduction and Safety This page intentionally left blank. Owner’s Manual for Mobile Generator...

  • Page 15: Section 2: General Information

    Section 2: General Information Specifications ® Description MDG25IF4 With VFLEX With SUPERSTART Engine ® Make (Model) — Isuzu (4LE2T) Isuzu (4LE2T) Isuzu (4LE2T) Rated Power Output hp (kW) 40 (30) 40 (30) 40 (30) Operating Speed 1,800 1,800 1,800 Fuel Consumption—100% load: gph (Lph) 2.3 (8.6), 2.0 (7.4)

  • Page 16: Unit Dimensions

    General Information ® Description MDG25IF4 With VFLEX With SUPERSTART Weight Skid Mounted—Dry lb (kg) 2,010 (911) 2,081 (944) 2,051 (930) Skid Mounted—Operating lb (kg) 2,450 (1,111) 2,521 (1,143) 2,491 (1,130) Trailer Mounted—Dry lb (kg) 2,247 (1,019) 2,318 (1,051) 2,288 (1,038) Trailer Mounted—Operating...

  • Page 17: Unit And Serial Number Locations

    General Information Unit and Serial Number Locations 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 these tags. Record the information from these tags in the event the tags are lost or damaged.

  • Page 18: Component Locations

    General Information Component Locations Exterior 011192 Figure 2-3. Exterior Components M Fuel drain (unit underside) Hot air/exhaust duct Coolant fill port Coolant drain Unit lift point Engine oil drain Telemetry (if equipped) Engine access door Fuel fill port Breaker and connection panel access door Tie-down point (4 locations) Emergency stop switch Generator access door...

  • Page 19: Interior

    General Information Interior 011193 Figure 2-4. Interior Components Engine oil fill Fuel pump Battery charger (if equipped) Primary fuel filter Generator phase switch M Coolant overflow container VFLEX switch (if equipped) Battery disconnect switch Generator Engine oil filter Air filter Connection panel Battery Receptacle Panel...

  • Page 20: Connection Panel

    General Information Connection Panel 011194 Figure 2-5. Connection Panel Main circuit breaker Connection lug (5 locations) Panel light Safety shutoff switch Service lights switch G Cam lock receptacle (5 locations) (if equipped) Neutral bonding bar Remote start terminal block Owner’s Manual for Mobile Generator...

  • Page 21: Receptacle Panel

    General Information Receptacle Panel 011195 Figure 2-6. Receptacle Panel 50 A circuit breaker (3 locations) LED light switch 20 A circuit breaker (2 locations) 120/240 V twist-lock receptacle (3 locations) Block heater power supply (if equipped) G Battery charger power supply (if equipped) 120 V GFCI receptacle (2 locations) Owner’s Manual for Mobile Generator...

  • Page 22: Control Panel

    General Information Control Panel 011196 Figure 2-7. Control Panel Genset controller Fuel transfer pump switch Door latch Interior cabin lights switch Voltage adjustment dial (potentiometer) G Low idle switch [not used] Controller power switch Owner’s Manual for Mobile Generator...

  • Page 23: Genset Controller

    General Information Genset Controller Figure 2-8. The genset controller displays real-time The controller is programmable. It can automatically start operational data, monitors functions of the generator and and stop the genset according to schedule, fault engine, shuts down the unit for certain fault conditions, condition, or load demand.
  • Page 24 General Information (A) Navigation Buttons Emergency Stop indicator LED. Figure 2-9. Used to navigate the operator pages. • Indicates Emergency Stop switch is active (pushed in). • Resolve deactivating (pulling out) Emergency Stop switch. Shutdown indicator LED. • 010418 Indicates a shutdown alarm is present. Figure 2-9.

  • Page 25: Controller Modes

    General Information (K) PAS valve test switch (if equipped) NOTE: To modify the AUTO mode programmed schedule, use the Deep Sea Configuration Suite software. When PAS test is active, the PAS is cycled to verify function. STOP/RESET Mode (L) MANUAL Mode LED STOP/RESET mode is distinguished by the following: •...
  • Page 26 General Information The Generator page displays the following generator The ECU Current DTC page displays active ECU DTCs. data, in real time (press ▲ or ▼ to scroll). Press ► to view previous ECU DTCs. • NOTE: See engine manual for information on ECU DTCs. Voltage (ph-N) •...

  • Page 27: Maintenance Alarms

    General Information Serial Port Page About 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.

  • Page 28: Voltage Selector Switch

    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 mechanically configures the generator main windings.

  • Page 29: Section 3: Operation

    Section 3: Operation Pre-start Checklist  Verify all electrical connections at the connection lugs, if equipped, are tight and wired correctly. All items in the pre-start checklist must be completed  Verify the voltage selector switch is set to the desired before starting the unit.

  • Page 30: Auto (Remote) Starting The Unit

    Operation cool. Pressing the ENTER () button will clear the 4. Remove the jumper wire from the remote start alarm and reset the controller. terminal block and the engine runs the stop sequence. Reconnect any necessary wires from NOTE: Engine preheat is controlled by the ECU. the remote start switch (transfer switch) to the 4.

  • Page 31: Low Idle Switch

    Operation Low Idle Switch Engine idle speed is 1,000 to 1,200 rpm. The engine will start at idle speed and run at idle for 15 seconds no matter what position the idle switch is in. After 15 seconds of running at idle, the unit will ramp up to 1,800 rpm if the idle switch is OFF.

  • Page 32: Using A Booster Battery Or Charger (If Equipped)

    Operation Using a Booster Battery or 5. Complete hookup making last connection of the NEGATIVE (-) cable to a good Charger (if equipped) ground on the engine frame and away from the batteries. WARNING 6. Start the engine. Disconnect jumper cables immediately after engine starts.

  • Page 33: Generator Cam Lock Connections (If Equipped)

    Operation The connection lug door is equipped with safety interlock Figure 3-5. The unit may be equipped with cam lock switches that will trip the main circuit breaker and disable connections (A), which are for powering external the voltage regulator if the door is opened while the unit electrical loads.

  • Page 34: Fine Voltage Adjustment

    Operation Fine Voltage Adjustment NOTE: When the voltage selector switch is in position for 480/277V three-phase, voltage at the two GFCI Figure 3-6. The potentiometer (A) allows manual receptacles is 139 volts and the voltage at the three twist- voltage adjustment of ±10%. lock receptacles is 240/139 volts.

  • Page 35: Transfer Switch

    Operation Transfer Switch DANGER Loss of life. Property damage. Installation must always comply with applicable codes, standards, laws and regulations. Failure to do so will result in death or serious injury. (000190) DANGER Electrical backfeed. Use only approved switchgear to 010493 isolate generator from the normal power source.

  • Page 36: Alternate Load Device (Ald)

    Operation down will not create any hazards by accidentally turning off equipment that needs to be kept on (pumps, compressors, lights, etc.). 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.

  • Page 37: Using The Ecu Override Switch

    Operation Using the ECU Override Switch PAS Test Procedure 1. Make sure generator battery is connected. CAUTION 2. Put Controller Power Switch in "ON" position, Insure the engine is not running. Equipment Damage. Do not start the engine with the 3.

  • Page 38: Towing The Unit

    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) WARNING Personal injury. Do not operate unit during transport. Doing so could result in death, serious injury, or 007620 property damage.
  • Page 39 Operation Tying Down the Unit IMPORTANT NOTE: Always remain aware of people and objects around the work site when moving or When securing the unit for transportation, verify the lifting the unit. equipment being used to fasten the unit is in good 3-13.
  • Page 40 Operation This page intentionally left blank. Owner’s Manual for Mobile Generator...

  • Page 41: Section 4: Maintenance

    Section 4: Maintenance Emissions Information General Maintenance For emissions information, see the OEM diesel engine Poorly maintained equipment can become a safety manual. 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 Maintenance any routine service (oil and oil filter changes, cleaning, Regular maintenance will improve performance and...

  • Page 42: Engine Oil Recommendations

    Maintenance • Coolant Recommendation 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 DANGER change in season or climate. Risk of poisoning. Do not use mouth to siphon –...

  • Page 43: Engine Break-In Requirements

    Maintenance Basic Maintenance Schedule First 50 Every 250 Every 500 Every Item Daily (Break-in 2,000 Hr Required Period) Check engine oil level ♦ Check engine coolant level ♦ Check fuel level ♦ Drain fuel filter ♦ Check tire pressure ♦ Check all electrical connections ♦...

  • Page 44: Resetting Maintenance Alarms

    Maintenance Resetting Maintenance Alarms Maintenance alarms indicate a regular-maintenance Grease service interval is expired. To resolve the condition, perform indicated service, then re-set corresponding service interval. To re-set a service interval: 1. Display the Engine page. 2. Scroll (▲ or ▼) until the appropriate service interval is highlighted.

  • Page 45: Section 5: Troubleshooting

    Section 5: Troubleshooting General Troubleshooting This information is intended to be a check or verification manual for additional troubleshooting information. Proce- for simple causes that can be located and fixed. It does dures that require in-depth knowledge or skills should be not cover all types of problems.
  • Page 46 Troubleshooting This page intentionally left blank. Owner’s Manual for Mobile Generator...

  • Page 47: Section 6: Wiring Diagrams

    Section 6: Wiring Diagrams Controls GROUP G COMPONENTS FOUND IN CONTROL BOX WIRING - DIAGRAM REVISION: B MDG25IF4-STD3 PAGE 1 OF 10 DRAWING #: A0000430348 DATE: 4/17/2020 Owner’s Manual for Mobile Generator...

  • Page 48: Control Box (1 Of 2)

    Wiring Diagrams Control Box (1 of 2) GROUP G COMPONENTS FOUND IN CONTROL BOX DCHR PASR ALDR ECUWS GND2 WIRING - DIAGRAM REVISION: B MDG25IF4-STD3 PAGE 2 OF 10 DRAWING #: A0000430348 DATE: 4/17/2020 Owner’s Manual for Mobile Generator...

  • Page 49: Control Box (2 Of 2)

    Control Box (2 of 2) GROUP G CONN3R CONN3P COMPONENTS FOUND ON THE CONTROL BOX CONN1R CONN1P CONN4P CONN4R CONN2P CONN7P CONN2R WIRING - DIAGRAM REVISION: B MDG25IF4-STD3 PAGE 3 OF 10 DRAWING #: A0000430348 DATE: 4/17/2020 Owner’s Manual for Mobile Generator...

  • Page 50: Generator Cabin (1 Of 2)

    GROUP G COMPONENTS FOUND IN GENERATOR CABIN CLC1 FLS1 CLC2 CCPS CRLS CRLC CRLC1 CLS1 CONN5P BATT GENERATOR GND1 CONN6P WIRING - DIAGRAM REVISION: B MDG25IF4-STD3 PAGE 4 OF 10 DRAWING #: A0000430348 DATE: 4/17/2020 Owner’s Manual for Mobile Generator...

  • Page 51: Generator Cabin (2 Of 2)

    COMPONENTS FOUND IN GENERATOR CABIN SBC1 SIREN OVR1 12VDC PASM FLD1 PASV HFF-1 50W 12VDC ALDC ALDC1 HFF-2 50W 12VDC TELEMETRY SCHEMATIC - DIAGRAM REVISION: B MDG25IF4-STD3 PAGE 5 OF 10 DRAWING #: A0000430348 DATE: 4/17/2020 Owner’s Manual for Mobile Generator...

  • Page 52: Generator Box-Vflex (If Equipped)

    Wiring Diagrams Generator Box—VFLEX (If Equipped) GROUP G COMPONENTS LOCATED IN GENERATOR BOX CONN5R PSAS GEN-GND VFLEX COMPONENTS VFB1 VFB2 WIRING - DIAGRAM REVISION: B MDG25IF4-STD3 PAGE 6 OF 10 DRAWING #: A0000430348 DATE: 4/17/2020 Owner’s Manual for Mobile Generator...
  • Page 53 Wiring Diagrams GROUP G COMPONENTS LOCATED INSIDE CUSTOMER CONNECTION PANEL CCLS CONN6R RSTB MLCB GND3 4PVRR 4PVRR VFVRR VFVRR WIRING - DIAGRAM REVISION: B MDG25IF4-STD3 PAGE 7 OF 10 DRAWING #: A0000430348 DATE: 4/17/2020 Owner’s Manual for Mobile Generator...
  • Page 54 COMPONENTS LOCATED IN GENERATOR BOX FRONT PS - 3 POSITION (Y-YY-Z) COMPONENTS LOCATED IN GENERATOR BOX FRONT PSAS PS - 4 POSITION (Y-YY-Z-D) WIRING - DIAGRAM REVISION: B MDG25IF4-STD3 PAGE 8 OF 10 DRAWING #: A0000430348 DATE: 4/17/2020 Owner’s Manual for Mobile Generator...
  • Page 55 Wiring Diagrams GROUP G COMPONENTS LOCATED IN GENERATOR BOX GND4 GFCI1 GFCIB1 GFCI2 GFCIB2 TLO1 TLB1 TLO2 TLB2 TLO3 TLB3 WIRING - DIAGRAM REVISION: B MDG25IF4-STD3 PAGE 9 OF 10 DRAWING #: A0000430348 DATE: 4/17/2020 Owner’s Manual for Mobile Generator...
  • Page 56 GROUP G COMPONENTS LOCATED IN GENERATOR CABIN PHILLIPS&TEMRO 420W 120V COMPONENTS LOCATED ON TRAILER AND TONGUE RSM2 ASM2 RSM1 ASM1 GND5 WIRING - DIAGRAM REVISION: B MDG25IF4-STD3 PAGE 10 OF 10 DRAWING #: A0000430348 DATE: 4/17/2020 Owner’s Manual for Mobile Generator...
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  • Page 58 Wiring Diagrams This page intentionally left blank. Owner’s Manual for Mobile Generator...
  • Page 60 Part No. A0000214097 Rev. A 06/18/2020 ©2020 Generac Mobile Products, LLC All rights reserved. Generac Mobile Products, LLC Specifications are subject to change without notice. 215 Power Drive, Berlin, WI 54923 No reproduction allowed in any form without prior written GeneracMobileProducts.com │800-926-9768 │920-361-4442 consent from Generac Mobile Products, LLC.

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