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46

Owner’s Manual for Mobile Generator

•

Polyfluoroethylene (PFE)

•

Polyvinylidene fluoride (PVDF)

•

Polytetrafluoroethylene (PTFE)

Materials  NOT  compatible  with  DEF  solutions  include

Aluminum, Magnesium, Zinc, Nickel coatings, Silver and

Carbon steel, and Solders containing any of the above.

Unexpected reactions may occur if DEF solutions come

in contact with any non-compatible material or unknown

materials.

Basic Maintenance Schedule

See  the  original  equipment  manufacturer’s  operating

manual for a complete list of maintenance requirements.

Failure to comply with the procedures as described in the

OEM  engine  manual  will  nullify  the  warranty,  decrease

performance,  and  cause  equipment  damage  or

premature equipment failure. Maintenance records may

be required to complete a warranty request.

NOTE: 

See  the  OEM  engine  manual  for  more

maintenance information.

Table 4-5. Basic Maintenance Schedule

Item

Daily Every 

250 Hr

Initial 

500 Hr

Every 

500 Hr

Every 

500 Hr/3 

Mo

Every 

500 Hr/1 

Year

Every 

2,000 Hr

Every 

2,500 Hr

Every 

3,000 Hr

Every 

4,000 Hr

Every 

5,000 Hr

Every 

6,000 Hr

Every 

10,000 

Hr

Every 

200,000 

Gal 

(760,00

0 L) of 

fuel or 

10,000 

Hr

Every 

12,000 

Hr or 6 

Yr

As 

Required

Air Tank 

Moisture 

and Sedi

-

ment - 

Drain

Cooling 

System 

Coolant 

Level - 

Check

Driven 

Equipment 

- Check

Engine Air 

Cleaner 

Service 

Indicator - 

Inspect

Engine Oil 

Level - 

Check

Fuel Sys

-

tem Pri

-

mary Filter / 

Water Sep

-

arator Drain

Walk-

Around 

Inspection

Engine Oil 

Sample - 

Obtain

Grounding 

Stud - 

Inspect, 

Clean, and 

Tighten

Engine 

Valve Lash 

- check

 

Battery 

Electrolyte 

Level - 

Check

Cooling 

System 

Supple

-

mental 

Coolant 

Additive 

(SCA) - 

Test/Add

Engine Oil 

and Filter - 

Change

Summary of Contents for MDE570P

Page 1: ...SAVE THIS MANUAL FOR FUTURE REFERENCE For technical assistance contact www generacmobileproducts com Technical Support 1 800 926 9768 Owner s Manual Diesel Generator MDE570P 014003 ...

Page 2: ...operation is performed promptly and to have the equipment checked periodically by a GMASD Normal maintenance service and replacement of parts are the responsibility of the owner or operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage may contribute to the need for additional maintenance or service Unit Mo...

Page 3: ...s 20 Maintenance Alarms 22 Fuel System 23 Fuel Tank 23 Engine Aftertreatment Monitoring 23 Alternator 24 Cold Weather Starting Aids If Equipped 25 Component Locations 25 Recommendations 25 Section 3 Operation Overview 27 Prestart Checklist 27 Cold Weather Operation 27 Using An External Battery Charger 28 Using Two Position Link Board 28 Lockout Function 29 Manually Starting the Unit 29 AUTO Remote...

Page 4: ...aintenance Schedule 46 Resetting Maintenance Alarms 49 DEF System Maintenance 49 DEF Testing 49 DEF Tank Cleaning 49 DEF Disposal 49 DEF Storage Guidelines 50 DOC SCR and DPF Cleaning Operations 50 Diesel Particulate Filter Regeneration 50 Regeneration Indicators 51 Modes of Regeneration 51 Regeneration Triggers 51 Regeneration System Warning Indicators 51 Checking Generator Drive Plate Torque 52 ...

Page 5: ...s service find service When contacting a GMASD about parts and service always supply the complete model and serial number of the unit as given on the data decal located on the unit Record the model and serial numbers in the spaces provided on the front cover of this manual Safety Rules The manufacturer cannot anticipate every possible circumstance that might involve a hazard The warnings in this m...

Page 6: ...t 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 Risk of injury Do not operate or service this machine if not fully alert Fatigue can impair the ability to operate or service this equipment and could result in death or serious injury 000215a WARNING 000182a WARNING Equipment damage On...

Page 7: ...GER 000164 WARNING Electrical shock Disconnect battery ground terminal before working on battery or battery wires Failure to do so could result in death or serious injury Personal injury Failure to properly connect lifting cables chains or straps could result in death serious injury or property damage 000346 WARNING WARNING 000349 Personal Injury Do not use lifting hook if there are signs of damag...

Page 8: ...s equipped with a frame grounding stud follow any local state and National Electrical Code NEC guidelines when connecting 000188 DANGER Electrocution Do not wear jewelry while working on this equipment Doing so will result in death or serious injury 000137a WARNING Explosion Batteries emit explosive gases while charging Keep fire and spark away Wear protective gear when working with batteries Fail...

Page 9: ...hich could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying Generac Mobile If NHTSA receives similar complaints it may open an investigation If it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in an ind...

Page 10: ... P65WARNINGS CA GOV DIESEL RESPIRAR EL ESCAPE DEL MOTOR DIESEL LO EXPONE A SUSTANCIAS QUÍMICAS QUE EL ESTADO DE CALIFORNIA RECONOCE COMO CAUSANTES DE CÁNCER Y DEFECTOS CONGÉNITOS U OTROS DAÑOS REPRODUCTIVOS 1 SIEMPRE ARRANQUE Y OPERE EL MOTOR EN UN ÁREA BIEN VENTILADA 2 SI ESTÁ EN UN ÁREA CERRADA VENTILE EL ESCAPE HACIA EL EXTERIOR 3 NO MODIFIQUE NI ALTERE EL SISTEMA DE ESCAPE 4 NO HAGA FUNCIONAR ...

Page 11: ...un immeuble doit être confié à un électricien compétent et respecter l ensemble des lois et codes en vigueur en matière d électricité 10000024164 5 6 7 8 9 10 11 2 WARNUNG ADVERTENCIA AVERTISSEMENT WARNING La génératrice peut démarrer automatiquement ce qui peut entraîner des blessures graves Débrancher la batterie avant de faire l entretien El generador puede arrancar automáticamente lo que puede...

Page 12: ...re commandé auprès de votre distributeur Generac local 10000023884 9 15 This equipment is factory configured per United States color coding standard L1 U BLACK BROWN L2 V RED ORANGE L3 W BLUE YELLOW NEUTRAL 0 WHITE GREY GROUND GREEN Cet équipement est configuré en usine selon la norme de codage couleur des États Unis L1 U NOIR BRUN L2 V ROUGE ORANGE L3 W BLEU JAUNE Neutre 0 BLANC GRIS Terre VERT D...

Page 13: ...requency Hz 60 Excitation Method PMG Power Output 3Ø Standby 208 120 VAC kW kVA A 460 575 1 598 240 139 VAC kW kVA A 500 625 1 505 480 277 VAC kW kVA A 500 625 753 3Ø Prime 208 120 VAC kW kVA A 456 570 1 584 240 139 VAC kW kVA A 456 570 1 372 480 277 VAC kW kVA A 456 570 686 Optional SUPERSTART Generator Make Model Leroy Somer LSA 47 2 M8 Frequency Hz 60 Excitation Method PMG Power Output 3Ø Stand...

Page 14: ...ities Standard Single Wall Fuel Tank Total gal L 760 2 876 Standard Single Wall Fuel Tank Usable gal L 671 2 540 Optional Double Wall Fuel Tank Total gal L 696 2 635 Optional Double Wall Fuel Tank Usable gal L 661 2 502 DEF Tank Total gal L 28 3 107 1 DEF Tank Usable gal L 24 7 93 5 Coolant Including Engine gal L 16 7 63 2 Oil Including Filter gal L 19 5 74 Run Time Fuel Tank 75 Load hr 27 1 AC Di...

Page 15: ...ual for Mobile Generator 11 Unit Dimensions Figure 2 1 Unit Dimensions H L W H L W 01348 L W H Skid Mounted 204 8 in 5 2 m 73 0 in 1 9 m 109 0 in 2 8 m Trailer Mounted 260 0 in 6 6 m 102 0 in 2 6 m 118 8 in 3 0 m ...

Page 16: ...erature This unit can provide full prime power up to 110 F 43 C ambient air temperature Above that operating the unit at full power causes the coolant to overheat resulting in engine shutdown Maximum coolant temperature is 225 F 107 C Wet Stacking This unit is powered by a diesel engine Wet stacking is a condition in diesel engines in which not all fuel is burned Unburned diesel fuel passes into t...

Page 17: ... underside R Generator access door F Extended run fuel system if equipped S 3 phase AC power distribution access door G Fuel fill T Emergency stop switch H Engine and generator genset access door U Breaker panel access door I Ladder V Stabilizer jack 2 locations if equipped J Spare tire 2 locations if equipped W Receptacle panel K Exhaust system access door X Control panel access door L Tie down p...

Page 18: ...lter P Breaker panel D Generator box Q Control panel E Oil level maintainer kit if equipped oil reservoir R fuel filters behind engine charge alternator F DEF tank S Engine charge alternator behind engine fan G Generator T Battery charger H Battery disconnect switch U Oil level indicator dipstick I Batteries V AC junction box if equipped J Crankcase ventilation CCV filter W Document holder K Radia...

Page 19: ...Distribution Panel Components 014006 A D F B C E G H I A Lug door safety switch F Emergency stop switch B Neutral bonding bar G Paralleling connection panel if equipped C Ground terminal H Charging lever D Terminal lug 4 locations I CLOSE OPEN button E Cam lock receptacle 30 locations if equipped ...

Page 20: ...ptacle Panel Components 014007 A B D C E A 125 V 15 A battery charger shore power plug 5 15P If equipped D 120 V 20 A GFCI duplex outlets NEMA 5 20R B Receptacle panel circuit breakers E 125 V 30 A winter heater shore power plug L5 30P If equipped C 240 V 50 A 3 pole twist lock outlet CS6369 ...

Page 21: ...r Mobile Generator 17 Component Locations Control Panel Figure 2 7 Control Panel Components A Panel light D Main lights switch B AUX fuel full switch E Genset controller C RUN IDLE switch F Hour meter 014008 A B C D E F ...

Page 22: ...serve the following guidelines when operating units in parallel configuration Paralleling equipped units can be connected ONLY to other paralleling equipped units Before operating units in parallel configuration verify each unit is operating correctly in accordance with this manual To verify the units intended for paralleling are appropriate for the load contact Generac Mobile at 1 800 926 9768 Se...

Page 23: ...start the engine Uses in this context are to check status of the CAN communication and to prime the engine When MANUAL mode is active the Engine Start button starts the generator NOTE In AUTO or STOP mode the Engine Start button activates the ECU G Alarm Mute and Lamp Test Button Stops the audible alarm and illuminates functional controller LEDs To test the LEDs press and hold button All LEDs illu...

Page 24: ...roller Modes NOTE See Operation for instructions on changing controller mode MANUAL Mode MANUAL mode is distinguished by full operator control of unit start up and shut down functions and by full operator control of generator load and unload functions AUTO Mode AUTO mode is distinguished by automation of unit start up and shut down functions and by automation of generator load and unload functions...

Page 25: ...umn varies according to generator make model and features NOTE As possible distribute electrical loads equally among generator lines Minor load imbalances 10 or less usually do not cause problems When loading generator observe the load amperage on each line Alarms Page Figure 2 14 Alarm Page The Alarms page displays active warnings and active alarms including engine DTCs ECU DTC Page Figure 2 15 E...

Page 26: ...trated Figure 2 18 Serial Port Page Modem Ready Program File Information Page Figure 2 19 Program File Information Page The Program File Information page displays the following controller information Controller model unit Program file name Program PN Program version About Page Figure 2 20 About Page The About page displays various general information about the unit and controller as illustrated Ma...

Page 27: ...unicate information to the operator The areas and the indicators that appear in those areas are explained here HEST Lamp High Exhaust System Temperature This area displays the regeneration underway indicator above the words HEST LAMP SOLID when the unit is in the process of the exhaust catalyst During the regeneration process the exhaust temperature will be very high DPF Regeneration Lamps Dependi...

Page 28: ...he module received an Amber fault condition from the engine ECU ECU Red Alarm The module received a Red fault condition from the engine ECU DPF Active The module received a fault indication from the engine ECU informing that the Diesel Particulate Filter is active DPF Inhibited The module received a fault indication from the engine ECU informing that the Diesel Particulate Filter has been inhibite...

Page 29: ...ng point of coolant Recommendations IMPORTANT NOTE The use of correct grade oil is critical to achieving adequate cold weather cranking speed Synthetic oils have improved flow at low tem peratures see Engine Oil Recommendations Starting aids may be required under the following conditions Cold weather When starting equipment with high parasitic loads during cranking and start acceleration to idle W...

Page 30: ... Mobile Generator NOTE See Table 2 1 for components in each package Table 2 1 Component Standard Package Extreme Package Block heater CCV heater Battery charger Fuel filter heater Oil heater Dual 4D batteries 60 40 coolant ...

Page 31: ...nding shroud are clear of debris Turn the battery disconnect switch ON Open the fuel shutoff valve Cold Weather Operation In cold environments units equipped with starting aids are recommended See Cold Weather Starting Aids If Equipped When starting a unit equipped with starting aids observe these guidelines Follow supplier instructions for starting aids provided on engine An optional 24 VDC 30 A ...

Page 32: ...3 1 A 24 VDC battery charger can be connected to the batteries to aid in cold weather starting ALWAYS use heavy duty jumper cables Figure 3 1 Connecting Battery Charger 1 Connect battery charger to a power source 2 Switch the battery disconnect switch to ON com pleting the circuit of the batteries connected in series This will allow charging of both batteries on the generator 3 Connect the POSITIV...

Page 33: ...s the AUTO MANUAL mode button to start MANUAL mode NOTE The controller can be started from any page when MANUAL mode is active 3 Press the green Engine START I button on the controller to initiate the engine startup process The unit starts if there are no engine faults prevent ing the unit from starting NOTE It may take a few seconds for the engine to run smoothly and reach operating speed During ...

Page 34: ... change in engine sound when a load is applied to the unit is normal AUTO Remote Starting the Unit IMPORTANT NOTE Before starting in AUTO mode review Prestart Checklist and Manually Starting the Unit Follow all safety warnings and review all infor mation on isolating the generator with a transfer switch if the unit will be used as a standby power source See Changing Exercise Timers then proceed in...

Page 35: ...t to ON 5 Set controller mode to MANUAL See Switching Controller Mode 6 Start each unit intended for paralleling Allow all to warm up 7 Press the Close Circuit Breaker button on each unit Automatic Paralleling 1 Verify the units to be paralleled are OFF 2 Secure all electrical connections to each unit and a common bus Before connecting ensure all wiring is properly color coded or labeled IMPORTANT...

Page 36: ...ed 6 Press and hold the CHECKMARK button to exit the Running configuration editor Voltage Regulator The voltage regulator controls the output of the generator by regulating current into the exciter field The voltage regulator is adjusted before shipment from the factory and typically does not require adjustment Main Circuit Breaker See Figure 3 10 The main circuit breaker is on the unit backside b...

Page 37: ...ough the opening Use a hex wrench to tighten the cable connections IMPORTANT NOTE There is permanent conductor between the generator stator winding and the frame The connection lug door is equipped with safety interlock switches If the door is opened when the unit is operating the interlock switches trip the main circuit breaker disable the voltage regulator and shut down the unit See Figure 3 12 ...

Page 38: ...ectrocution 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 000237 DANGER Electrical backfeed Use only approved switchgear to isolate generator from the normal power source Failure to do so will result in death serious injury and equipment damage WARNING 000308 Electric Shock Verif...

Page 39: ...ceptacle delivers 120 VAC and each twist lock receptacle delivers 208 120 V When the link board set to 600 346 VAC 3 phase the buck transformer is not capable of stepping down voltage to an acceptable range Generac Mobile does not recommend using the receptacles in the 600 V position Transfer Switch The installation should be in compliance with the National Electrical Code NEC and state and local ...

Page 40: ... must continue operating such as pumps compressors lights 1 Remove all loads from the generator by opening all circuit breakers turn to the OFF O position 2 Allow engine to run for approximately five minutes to allow it to cool down 3 Press the red engine STOP RESET O button on the controller 4 After pressing the red engine STOP RESET O button the unit may continue to run for an addi tional cool d...

Page 41: ...t the angle of the trailer tongue to keep the trailer as level as possible Preparing Unit for Towing 1 Verify engine is OFF 2 Use the tongue jack to raise or lower the trailer onto the hitch of the towing vehicle Lock the hitch coupling and attach the safety chains or cables to the vehicle Raise the tongue jack to the highest positions providing the maximum clearance between the ground and the jac...

Page 42: ...s and lift chains that are appropriately rated for this machine Attach chain to 4 point lift eyes B See unit dimensions Figure 3 18 Trailer Mounted Unit NOTE See Figure 3 19 Do NOT connect lifting equipment to indicated holes A Figure 3 19 NOT Lifting Points Four Locations See Figure 3 18 item B for the correct lifting points Skid Mounted Units ONLY Skid mounted units can be lifted multiple ways S...

Page 43: ...on the front and rear of the machine 2 Attach the chains to a suitable tow vehicle B NOTE The D Rings are not to be used for lift the entire generator D Rings are designed for dragging generator on skid frame Tying Down the Unit When securing the unit for transportation verify the equipment being used to fasten the unit is in good condition and has sufficient strength to hold the unit in place dur...

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Page 45: ...hes the red section on the gauge 20 in H2O Inspect condition of electrical cords DO NOT use the unit if insulation is cut or worn through Check tire pressure lug nut torque and axle oil bath levels according to manufacturers recommendations If unit is going to be stationary for extended period daily checks of the wheels and axles are not required If unit has been stationary for an extended period ...

Page 46: ...nt or fuel tank drain If fuel ever needs to be drained from tank it should be pumped out of the tank and into a proper container The optional fuel tank does come equipped with fuel containment and a rupture basin alarm This alarm will display a warning message on the controller display The fuel can be drained from the containment basin using the drain plug located on the bottom of the tank Engine ...

Page 47: ...s and must not be used CC CD CD 2 CF 4 CG 4 CH 4 and CI 4 Lubricant Viscosity Recommendations for Direct Injection DI Diesel Engines The correct SAE viscosity grade of oil is determined by the minimum ambient temperature during cold engine start up and the maximum ambient temperature during engine operation See Figure 4 1 minimum temperature to determine the required oil viscosity for starting a c...

Page 48: ...ion Analysis determines the loss of the oils lubricating properties An infrared analysis is used to compare the properties of new oil to the properties of the used oil sample This analysis allows technicians to determine the amount of deterioration of the oil during use This analysis also allows technicians to verify the performance of the oil according to the specification during the entire oil c...

Page 49: ...is will allow the tank vent to function properly and prevent any blockage to occur in the fill neck of the tank DEF Quality DEF quality can be measured with a refractometer The DEF must comply with ISO standard 22241 1 with the urea solution of 32 5 Cleanliness Contaminants can degrade the quality and life of DEF Filtering DEF is recommended when dispensed into the DEF tank Filters should be compa...

Page 50: ...ilure Maintenance records may be required to complete a warranty request NOTE See the OEM engine manual for more maintenance information Table 4 5 Basic Maintenance Schedule Item Daily Every 250 Hr Initial 500 Hr Every 500 Hr Every 500 Hr 3 Mo Every 500 Hr 1 Year Every 2 000 Hr Every 2 500 Hr Every 3 000 Hr Every 4 000 Hr Every 5 000 Hr Every 6 000 Hr Every 10 000 Hr Every 200 000 Gal 760 00 0 L o...

Page 51: ... Engine Mounts Inspect Starting Motor Inspect ARD Spark Plug Emis sion Related Compo nent Clean Diesel Exhaust Fluid Filter Emission Related Compo nent Replace Diesel Par ticulate Fil ter Emission Related Compo nent Clean Table 4 5 Basic Maintenance Schedule Item Daily Every 250 Hr Initial 500 Hr Every 500 Hr Every 500 Hr 3 Mo Every 500 Hr 1 Year Every 2 000 Hr Every 2 500 Hr Every 3 000 Hr Every ...

Page 52: ...Filter Screen Emission Related Compo nent Clean Diesel Exhaust Fluid Emis sion Related Compo nent Clean Engine Clean Engine Air Cleaner Element Replace Fuel Sys tem Prime Fuel Tank Water and Sediment Drain Radiator Clean Table 4 5 Basic Maintenance Schedule Item Daily Every 250 Hr Initial 500 Hr Every 500 Hr Every 500 Hr 3 Mo Every 500 Hr 1 Year Every 2 000 Hr Every 2 500 Hr Every 3 000 Hr Every 4...

Page 53: ...h a handheld refractometer calibrated to measure DEF DEF concentration should be checked when the engine has been stored for extended periods or if there is suspicion the engine or packaged DEF has been contaminated with water Follow the instructions included with either tool to obtain the measurement The correct DEF concentration is 32 5 urea If the DEF concentration is not within specification d...

Page 54: ...Storing DEF at higher temperatures can reduce its useful life by approximately six months for every 9 F 5 C above 86 F 30 C Long term storage in the DEF tank over 12 months is not recommended If long term storage is necessary test DEF before operating engine See DEF Testing DOC SCR and DPF Cleaning Operations The exhaust aftertreatment system goes through an automatic cleaning process known as reg...

Page 55: ...ithout interruption The DPF indicator will shut off when regeneration is complete If the soot load is above a threshold or sulfur is high then regeneration is required The DPF indicator will illuminate and flash slowly Engine power will be slightly derated If the machine continues to operate without regeneration derate will eventually reach 100 Stop the machine With the engine at low idle initiate...

Page 56: ...e If equipped the axle bolt and nut assembly of the caster wheel must also be lubricated with the same lightweight oil Table 4 6 Regeneration Triggers Type Reason For Trigger Strategy Regen Interval Duration Minutes Primary Triggers LSR HSR A T maintenance Upon cold startup coolant temp below 104 F 40 C the A T will be maintained Coolant temp must reach 104 F 40 C before regeneration will occur Sh...

Page 57: ...equired The oil seal is a 2 part seal where the inside diameter of the seal presses onto the spindle journal and the outside diameter of the seal presses into the hub bore A gear puller is the most efficient way to remove the hub from the spindle A new oil seal must be installed before reassembly or the old seal will leak upon re installation and use When re installing a new oil seal be sure to co...

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Page 59: ...Low coolant level shutdown Low coolant level Allow engine to cool then check coolant level in radiator Add coolant if necessary Leaking coolant hoses Inspect hoses for leaks Repair or replace as necessary Leaking engine block or water pump Visually inspect for leaks Verify no coolant has mixed with the engine oil oil will appear milky See the OEM engine manual for additional information High coola...

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Page 77: ...Owner s Manual for Mobile Generator 73 Wiring Diagrams A0003446546_A_10 19 22 ...

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Page 80: ...rights reserved Specifications are subject to change without notice No reproduction allowed in any form without prior written consent from Generac Power Systems Inc Generac Power Systems Inc S45 W29290 Hwy 59 Waukesha WI 53189 GeneracMobileProducts com 844 ASK GNRC 844 275 ...

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