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Summary of Contents for Generac Power Systems MAGNUM MDG20IF4
- Page 1 DIESEL GENERATOR MDG20IF4 • MLG20IF4 With Controller OPERATING MANUAL 01623 www.discount-equipment.com 37100 B 11/15...
- Page 2 Discount-Equipment.com is your online resource for commercial and industrial quality parts and equipment sales. Locations: Florida (West Palm Beach): 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Check out our website at www.discount-equipment.com Can’t find what you need? Click on this link: http://www.discount-equipment.com/category/5443-parts/ and fill out the request form.
- Page 3 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. 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 4: 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. The information contained in this manual was based on machines in production at the time of publication. -
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 6 - Wiring Diagrams AC Wiring ............................31 AC Wiring - Customer Convenience Receptacles................32 AC Wiring - Customer Convenience Receptacle Options (1 of 2)............ 33 AC Wiring - Customer Convenience Receptacle Options (2 of 2)............ 34 DC Wiring ............................35 DC Wiring Options..........................
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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 TOWING SAFETY Towing a trailer requires care. Both the trailer and vehicle must be in good condition and securely fastened to each other to reduce the possibility of an accident. Some states require that large trailers be registered and licensed. Contact your local Department of Transportation office to check on license requirements for your particular unit. -
Page 10: Safety Symbol Summary
Safety 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. Decal placement and part numbers can be found in the online parts manual at www.generacmobile.com. -
Page 11: Section 2 - General Information
Section 2 - General Information SPECIFICATIONS GENERAC MODEL MDG20IF4 • MLG20IF4 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: Unit Dimensions
General Information Unit Dimensions 00847 Figure 1 - Unit Dimensions MDG20IF4 • MLG20IF4 105 in. (2.67 m) 56 in. (1.42 m) 68 in. (1.73 m) Specifications are subject to change without notice. UNIT SERIAL NUMBER LOCATIONS Refer to the illustration to locate the unit ID tag and Vehicle Identification Number (VIN) tag on the unit. Important information, such as the unit serial number, model number, VIN and tire loading information are found on these tags. -
Page 13: Component Locations
General Information COMPONENT LOCATIONS 02029 Figure 3 - Component Locations 1. Radiator access panel 5. Ground stud 2. Battery and engine access 6. Tongue jack 3. Customer convenience receptacles 7. Emergency stop switch 4. Control panel access 8. Fuel fill access 37100 B MDG20IF4-MLG20IF4 Operating Manual... -
Page 14: Control Panel
General Information CONTROL PANEL Select 02028 Figure 4 - Control Panel Component Locations 1. Power Zone™ controller 4. DC breaker 2. Main circuit breaker 5. Control power switch 3. Remote start terminal block MDG20IF4-MLG20IF4 Operating Manual 37100 B... -
Page 15: Power Zone™ Light Controller
General Information POWER ZONE™ LIGHT CONTROLLER The Power Zone™ 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 16: Operator Screens
General Information Start Mode This button will start the engine, provided there are no shutdown errors, and the engine satisfies the start status. Stop Mode This button will shut down the unit and put the controller into Stop mode, whether in Manual mode or Auto mode. CAUTION In case of an emergency, always press the emergency stop switch located on the front of the unit to stop the engine immediately. - Page 17 General Information AUTO AUTO MANUAL MANUAL HRS 2 hr SRV 7 hr STATUS At Rest 01968 Figure 7 - Home Screen Engine Screen The Engine screen will display the battery voltage, oil pressure, coolant temperature and fuel level. • VBAT: Displays the engine battery voltage. A normal reading is 12-14V on 12 volt systems and 24-26V on 24 volt systems (with the engine running).
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Page 18: Maintenance Screens
General Information Maintenance Screens The information displayed on the maintenance screens can be used to identify, diagnose and troubleshoot unit shutdown conditions and poor unit performance. To enter the navigation menu, use the following procedure: 1. Press both the ↑ and ↓ buttons simultaneously. 02012 Figure 10 - Navigation Menu 2. -
Page 19: Possible Dtc Faults
General Information The controller will automatically return to this screen from any other screen after a period of inactivity. AUTO AUTO MANUAL MANUAL HRS 2 hr SRV 7 hr STATUS At Rest 01968 Figure 11 - Home Screen (Manual Mode Shown) Alarms Screen The Alarms ( ) screen(s) will display all the alarms, warnings, engine DTC alarms, and the trouble codes. - Page 20 General Information Table 2: Possible DTC Faults Fault DTC Description The engine ECU has detected that the engine speed has risen Over Speed above its configured over speed alarm level. The engine ECU has detected that the engine’s fuel level has Low Fuel Level fallen below its configured low fuel level alarm.
- Page 21 General Information 15/15 0 h 01 mins 05 22PM 08/11/15 Digital input B Restart 01973 Figure 14 - Event Log Screen To view the event log, press both ↑ and ↓ buttons simultaneously, the navigation menu is then displayed. Once entered, cycle to the event log section and press the Auto button to enter.
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Page 22: Section 3 - Operation
Section 3 - Operation PRESTART CHECKLIST Before starting the unit, all items in the prestart checklist must be completed. 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 23: Auto (Remote) Starting Of The Unit
Operation 8. Check that the frequency (Hz) is correct on the Generator screen. With no loads connected to the generator, the frequency should read approximately 60 Hz, depending on the type of engine governing used. 9. If all wiring connections have been made correctly, switch the main circuit breaker to the ON (I) position and then add any loads attached to the receptacles by switching the respective circuit breaker to the ON (I) posi- tion. -
Page 24: Customer Convenience Receptacles
Operation occurs when an engine is run at less than 30% of its full load capacity, causing unburned fuel to accumulate in the exhaust system. Wet stacking can be detected by continuous black exhaust when the unit is under a constant load. It can also cause fouling of injectors and buildup on engine valves. -
Page 25: Auto Exercise Timer
Operation Emergency Incoming Distribution Panel Utility (Generator Power) Power Main WHITE = Incoming Distribution Panel Utility Power (Utility Power) Utility GRAY = Normal Utility Meter Power Circuit Transfer Switch BLACK = Emergency Generator Power Circuit Power From Generator 00206 Figure 17 - Transfer Switch Operation DANGER FAILURE TO ISOLATE THE GENERATOR FROM THE NORMAL POWER UTILITY CAN CAUSE POTENTIALLY LETHAL VOLTAGE TO BACKFEED INTO THE UTILITY LINES. -
Page 26: Accessing The Scheduler
Operation Accessing the Scheduler 1. Press ↑ or ↓ until the scheduler screen is displayed. SCHEDULER SCHEDULER PRESS SELECT TO TURN ON OR OFF PRESS SELECT TO TURN ON OR OFF 02014 Figure 18 - Scheduler Screen 2. Press to either enable or disable the scheduler. When the scheduler is on, the seven scheduler screens will become active. -
Page 27: Set The Unit To Auto Mode
Operation 1. With the Scheduler on, press ↓ to enter the scheduler starting with Monday. 08/28/2015 12 29PM MONDAY MONDAY START START 09 36 PM DURATION DURATION 10hrs 00mins PRESS SELECT TO EDIT 02015 Figure 20 - Monday Scheduler a. To edit the day, use ↑ or ↓ to get to the desired day. Press to turn the day on or off. b. -
Page 28: Emergency Stop
Operation EMERGENCY STOP The unit is equipped with one emergency stop switch. For location of the emergency stop switch, refer to “Component Locations”. The red button is clearly labeled “EMER- GENCY STOP.” The switch can be accessed and activated with all doors closed and locked. -
Page 29: Lifting The Unit
Operation LIFTING THE UNIT A central lift point is located on the top of the unit. The central lift point is connected to a lift structure inside the unit. Attach a sling or hook directly to the central lift point only if the devices are in good condition and the equipment being used to raise the unit has sufficient capacity. -
Page 30: Section 4 - Maintenance
Section 4 - Maintenance Normal maintenance service and replacement of parts are the responsibility of the owner/operator and, as such, are not considered defects in materials or workmanship within the terms of the warranty. It is strongly recommended that the equipment be periodically checked by a Generac Mobile Products Authorized Dealer. 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. -
Page 31: Basic Maintenance Schedule
Maintenance ○ 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. DO NOT OVERFILL the crankcase. -
Page 32: Jack Maintenance
Maintenance The maintenance or service interval is set at 250 and 500 hours of engine running time. Once the unit has been serviced, the appropriate maintenance alarm reminder needs to be reset. The following procedure demonstrates how to reset the maintenance alarms: 1. -
Page 33: Top-Wind Models
Maintenance Top-Wind Models • Apply a lightweight oil to the screw stem. Grease Grease Grease 00243 Figure 26 - Lubrication Points TRAILER WHEEL BEARINGS The trailer axles are equipped with a grease zerk fitting to allow lubrication of the wheel bearings without the need to disassemble the axle hub. -
Page 34: Section 5 - Troubleshooting
Section 5 - Troubleshooting GENERAL TROUBLESHOOTING Some of the more common problems are listed in the table below. This information is intended to be a check or verification that simple causes can be located and fixed. It does not cover all types of problems. Refer to the engine operator’s manual for additional troubleshooting information. -
Page 35: Section 6 - Wiring Diagrams
Section 6 - Wiring Diagrams AC WIRING MAIN BREAKER MAIN CIRCUIT BREAKER TO RECEPTACLES 100A TO RECEPTACLES SE350 GN/YL VOLTAGE REGULATOR 4 AMP FUSE TO CNTRL 24 ON REGULATOR 90552_B_11.13.14 37100 B MDG20IF4-MLG20IF4 Operating Manual... -
Page 36: Ac Wiring - Customer Convenience Receptacles
Wiring Diagrams AC WIRING - CUSTOMER CONVENIENCE RECEPTACLES TO MAIN BREAKER TO NEUTRAL TO GROUND (2x5-20R, 1xTT-30, 1xL14-30R, 2x14-50) 90317_ORG_07.06.11 MDG20IF4-MLG20IF4 Operating Manual 37100 B... -
Page 37: Ac Wiring - Customer Convenience Receptacle Options (1 Of 2)
Wiring Diagrams AC WIRING - CUSTOMER CONVENIENCE RECEPTACLE OPTIONS (1 OF 2) 30 AMP 30 AMP 50 AMP 50 AMP CIRCUIT CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER BREAKER BREAKER 20 AMP 20 AMP CIRCUIT CIRCUIT BREAKER BREAKER 240 VOLT 240 VOLT 240 VOLT 240 VOLT 30 AMP... -
Page 38: Ac Wiring - Customer Convenience Receptacle Options (2 Of 2)
Wiring Diagrams AC WIRING - CUSTOMER CONVENIENCE RECEPTACLE OPTIONS (2 OF 2) 30 AMP 30 AMP 30 AMP 50 AMP CIRCUIT CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER BREAKER BREAKER 20 AMP 20 AMP CIRCUIT CIRCUIT BREAKER BREAKER 240 VOLT 240 VOLT 240 VOLT 240 VOLT 30 AMP... -
Page 39: Dc Wiring
Wiring Diagrams DC WIRING 90551_A_09.19.14 37100 B MDG20IF4-MLG20IF4 Operating Manual... -
Page 40: Dc Wiring Options
Wiring Diagrams DC WIRING OPTIONS 90323_K_06.04.14 MDG20IF4-MLG20IF4 Operating Manual 37100 B... -
Page 41: Trailer Lights Wiring
Wiring Diagrams TRAILER LIGHTS WIRING 90341_B_12.20.13 37100 B MDG20IF4-MLG20IF4 Operating Manual... -
Page 42: Section 7 - Options & Accessories
Section 7 - Options & Accessories LOWER RADIATOR HOSE HEATER OPTION - USE AND MAINTENANCE CAUTION Improper use of the lower radiator hose heater could result in damage to the engine or personal injury. Do not modify the location of the lower radiator hose heater. The following points should be followed when operating a unit equipped with a lower radiator hose heater. -
Page 43: 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 44 www.discount-equipment.com...
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