Generac Mobile MMG35DF4 Owner'S Manual Download

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Owner’s Manual for Mobile Generator

Wiring Diagrams

Trailer Brakes

TTER

BREAKA

SWITCH

BRAKE

NDEM AXLE

BRAKE

TRI-AXLE

SINGLE AXLE

SPLICE

FRAME GND

90286_E_03.18.14

Summary of Contents for MMG35DF4

Page 1: ...S MANUAL FOR FUTURE REFERENCE For technical assistance contact www generacmobileproducts com Technical Support 1 800 926 9768 Owner s Manual Diesel Generator MMG35DF4 MMG45IF4 MMG55DF4 Up to SN 3005615838 01306 ...

Page 2: ...ent checked periodically by a GMASD 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 Individual operating habits and usage may contribute to the need for additional maintenance or service Unit Model No Unit Serial No Engine Model No Engine Serial No Ge...

Page 3: ...O Remote Starting the Unit 26 Low Idle Switch 26 Wet Stacking 26 Cold Weather Operation 27 Using a Booster Battery or Charger if equipped 28 Generator Output Connections 28 Generator Cam Lock Connections If Equipped 29 Using the Voltage Selector Switch 29 Fine Voltage Adjustment 30 Voltage Regulator 30 Customer Convenience Receptacles 30 Main Circuit Breaker 30 DOC and SCR Cleaning Operations 30 D...

Page 4: ...e Wind Models 42 Top Wind Models 42 Trailer Wheel Bearings 42 Section 5 Troubleshooting General Troubleshooting 43 Section 6 Wiring Diagrams 3 Position AC Box 45 3 Position AC Box 46 4 Position AC Box 47 4 Position AC Box 48 Receptacles 49 Engine Heater 49 Wiring Buck If Equipped 50 Power Zone PMG 50 Control Box 51 Trailer Lights 52 Trailer Brakes 53 12 Volt Battery Charger 54 Power Zone Low Oil L...

Page 5: ...ts 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 pro vided 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...

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

Page 7: ...us injury DANGER 000238 Explosion Batteries emit explosive gases Always disconnect negative battery cable first to avoid spark Failure to do so could result in death or serious injury WARNING Personal injury Failure to properly connect lifting cables chains or straps could result in death serious injury or property damage 000346 WARNING WARNING Personal Injury Do not use lifting eye if there are s...

Page 8: ...put Equipment connected to the unit overheats Sparking occurs Engine misfires or there is excessive engine gen erator vibration Protective covers are loose or missing Ambient air temperature is above 120 F 49 C 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 whil...

Page 9: ... 108 148 Nm Figure 1 2 Lowering Tongue Trailer NOTE If the jack was used to support the unit while removing the shipping brace the jack must be moved back to the tongue location before the unit can be towed Connect the trailer tongue to a vehicle or other support and move the jack to the tongue location 5 Tighten the bolt inside the jack mounting tube nearest the frame 6 See Figure 1 3 Remove the ...

Page 10: ... space between vehicles and avoid soft shoulders curbs and sudden lane changes 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 immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying Generac Mobile If NHTSA receives similar complaints it may open an investigati...

Page 11: ...Operating Instructions 3 Danger Diesel Fuel 21 Terminal Connections Voltage Selector Switch 4 Tie Down Location 22 Electrical Backfeed Danger 5 Oil Drain 23 Remote Start Terminal Connections 6 Coolant Drain 24 Neutral Bonded to Frame 7 Warning Hot Surface 25 CAM Locks 8 Unit Lift Point 26 Connection Terminal Lugs 9 Warning Automatic Starting 27 Fan Clutch if equipped 10 Electric Shock Hazard 28 Fu...

Page 12: ...YHKtFXOR GH UHPROTXH QJDQFKH ODV FDGHQDV GH VHJXULGDG HQ IRUPD FUX DGD QJDQFKH DO YHKtFXOR OD FDGHQD GH HPHUJHQFLD SDUD DYHUtDV 5HYLVH ODV OXFHV GHO UHPROTXH 6 33 1 681 1 LUH OH PDQXHO GH O XWLOLVDWHXU 8WLOLVHU XQ DWWHODJH FRQYHQDQW DX SRLGV QRPLQDO EUXW GH OD UHPRUTXH UULPHU VROLGHPHQW OD UHPRUTXH DX YpKLFXOH WUDFWHXU 3RVHU OHV FKDvQHV GH VpFXULWp HQ OHV FURLVDQW L HU OD FKDvQH GH UHPRUTXDJH DX Y...

Page 13: ...conecte la batería antes de realizar el servicio técnico BATTERY DISCONNECT HINWEIS AVISO AVIS NOTICE PRIMARY FILTER SECONDARY FILTER OPEN UPPER DOOR FIRST TO ACCESS CONNECTIONS La génératrice peut démarrer automatiquement ce qui peut entraîner des blessures graves Débrancher la batterie avant de faire l entretien Generator can automatically start which can cause serious injury Disconnect battery ...

Page 14: ...sconecte todas las cargas externas 2 Configure el interruptor del selector de voltaje 3 Jale el botón de parada de emergencia 4 Mueva el interruptor de control a la posición CONTROL ON control encendido 5 Empuje el botón ENGINE START arrancar motor Arranque remoto 1 Consulte el manual del operador Parada 1 Desconecte todas las cargas externas 2 Empuje el botón ENGINE STOP parar motor 3 Mueva el in...

Page 15: ...0 4 Generator Make Model Marathon 284CSL1542 Marathon 285PSL1700 Marathon 286PSL1701 Insulation Class H H H Poles qty 4 4 4 Voltage Regulation AVR AVR AVR Frequency Hz 60 60 60 Power Output 3Ø Standby kW kVA 31 39 44 55 48 60 208 480 V A 108 47 153 66 167 72 240 V A 94 122 144 3Ø Prime kW kVA 29 36 38 47 44 55 208 480 V A 100 43 130 57 153 66 240 V A 86 114 122 1Ø Standby kW kVA 30 30 40 40 46 46 ...

Page 16: ...Generator General Information Unit Dimensions Figure 2 1 Unit Dimensions MMG35DF4 MMG45IF4 MMG55DF4 L W H Skid Mounted 95 in 2 41 m 39 in 0 99 m 65 in 1 65 m Trailer Mounted 152 in 3 81 m 58 in 1 45 m 83 in 2 11 m H W L H W L 01906 ...

Page 17: ...tags in the event the tags are lost or damaged This information may be needed when ordering parts or requesting assistance Figure 2 2 Unit and Serial Number Locations Altitude and Temperature Limitations All units are subject to derating for altitude and temperature this will reduce the available power for operating tools and accessories connected to the outlets Typical reductions in performance a...

Page 18: ...t I Breaker panel access door B Radiator access panel J Coolant and oil drain C Unit lift point K Lug box access door D Fuel fill port L Receptacle panel E Side marker M Emergency stop switch F Rear stabilizer mount N Tail light 2 locations G Tie down point O Control panel access door H Tongue jack A M N L J I G F E B H D C O K 008881 ...

Page 19: ...aker 3 locations K Cam lock receptacle 5 locations if equipped D Service lights switch L 120V 240V twist lock outlets E 20A circuit breaker 2 locations M Connection for optional equipment Inlet F Lug door safety switch N 120 V GFCI outlet 2 locations G Remote start terminal block O Connection for battery charger if equipped H Neutral grounding bar P Emergency stop switch 01882 O N M L K J I H G F ...

Page 20: ...el Figure 2 5 Control Panel Components A Genset controller F Generator lights switch B Panel light G Engine speed switch C Voltage selector switch H Controller power switch D not used I Voltage adjustment dial Potentiometer E Fuel transfer switch C E F H G A B 008882 D I ...

Page 21: ...ondition or load demand Figure 2 6 Genset Controller Deep Sea Model DSE7310 MKII A Navigation buttons J Positive air shutoff PAS valve test switch LED if equipped B Screen K PAS valve test switch if equipped C Indicator LED 4 locations L MANUAL Mode LED D Transfer to Generator button M MANUAL Mode button E Generator Available LED N Engine STOP RESET Mode button F Engine START button O Engine STOP ...

Page 22: ...ommunication 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 illuminate When button is released the LEDs switch off NOTE If an LED does...

Page 23: ...ctions 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 AUTO mode utilizes the remote start connections For remote starting procedures see Section 3 Operation AUTO mode utilizes a programmed schedule which can be modified NOTE To mo...

Page 24: ...se problems When loading generator observe the load amperage on each line Alarms Page Figure 2 10 Alarm Page The Alarms page displays active warnings and active alarms including engine DTCs ECU DTC Page Figure 2 11 ECU DTC Page Current DTCs The ECU Current DTC page displays active ECU DTCs Press to view previous ECU DTCs NOTE See engine manual for information on ECU DTCs NOTE All DTCs display on t...

Page 25: ...igure 2 15 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 16 About Page The About page displays various general information about the unit and controller as illustrated Maintenance Alarms Maintenance alarms indicate a regular maintenance service inte...

Page 26: ...tor above the words SCR LAMP SOLID when auto exhaust filter cleaning is enabled When the unit is being operated with auto exhaust filter cleaning disabled the indicator will begin to flash above the words SCR LAMP FLASHING if the soot load level goes above 80 SCR Inhib This area displays the disabled regeneration indicator above the words SCR INHIB SOLID when auto exhaust filter cleaning is disabl...

Page 27: ...voltage selector switch is equipped with a lockout mechanism When engaged the switch is locked in place preventing configuration changes NOTE See Using the Voltage Selector Switch for more information 3 Position Switch 4 Position Switch Available Configurations Hi wye Low wye Zig zag Hi wye Low wye Zig zag Delta 000302 WARNING Electric Shock Never change the voltage selector switch while the engin...

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Page 29: ...er begins its boot sequence When controller is ready the Home page displays NOTE The controller boots in STOP mode as indicated at the top of the screen NOTE If starting the unit in cold ambient temperatures it is recommended to start the unit at low idle and allow the engine to heat up the lubricating oil For more information see Low Idle Switch NOTE The controller can be started from any screen ...

Page 30: ...om the remote start terminal block Press the AUTO button and the display screen will show auto mode at the bottom of the screen 3 Attach a jumper wire minimum 16 gauge across the two terminals on the remote start terminal block This applies a ground to the controller to close the starting circuit contacts The engine will crank start and run 4 Remove the jumper wire from the remote start terminal b...

Page 31: ...ntact a GMASD or refer to the applicable engine service manual for more information 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 block heater is powered by a shore power 120V electrical connection that can be found in the convenience receptacle The crankcase ventilation heater is powered by the generator...

Page 32: ...g door details the proper connections for selected voltages Connections to the lugs should be made by running the power cables up through the opening in the bottom of the box IMPORTANT NOTE Do not make any connections directly to the lugs without routing the cables through the opening Use a hex wrench to tighten the cable connections 000137a WARNING Explosion Batteries emit explosive gases while c...

Page 33: ...must be removed when the generator is used as a standby power source Installation should be in compliance with the National Electrical Code NEC state and local regulations Using the Voltage Selector Switch 1 Shut down the unit according to Shutting Down the Unit 2 Remove padlock from voltage selector switch lockout device 3 Move voltage selector switch to desired voltage 007618 B A 000156 DANGER E...

Page 34: ...r is located on the main control panel See Figure 2 4 When the breaker is OFF O power is interrupted to the connection lugs the optional cam lock receptacles and the generator The breaker may be switched ON I once the connections have been made to the connection lugs or the optional cam lock receptacles and the unit has been started and allowed to reach normal operating temperature NOTE Main circu...

Page 35: ...nable the auto exhaust after treatment cleaning feature 1 Locate the REGEN INHIBIT on the outside of the control panel under the display 2 Set the switch to ON AUTO I O 3 Enter the SCR status screen and verify the re generation indicator appears above the words SCR LAMP SOLID See Selective Catalytic Reduction SCR Monitoring Transfer Switch The installation should be in compliance with the National...

Page 36: ...for five seconds To cancel any changes and return to the maintenance screen press and hold O for five seconds Set the Controller Clock The schedule runs based on the time set in the controller clock Proceed as follows to set the controller clock before setting the schedule 1 Navigate to the maintenance group and press to access it 2 Press to select the time section 3 Set the time and date to the c...

Page 37: ...extended storage time disconnect the battery See the engine operator s manual for extended storage requirements Emergency Stop Switch See Figure 2 5 The unit is equipped with one emergency stop switch The red button is clearly labeled EMERGENCY STOP The switch can be accessed and activated with all doors closed and locked Activate the emergency stop switch by pushing the button in until it locks d...

Page 38: ...nt being used to lift the unit is in good condition and has sufficient capacity 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 a Start all lug nuts by hand b First pass tighten to 20 25 ft lb 27 33 Nm c Second pass tighten to 50 60 ft lb 67 81 Nm d Third pa...

Page 39: ...igure 3 8 Central Lift Point 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 during transport See Figure 3 9 Use the tie down points A as shown Figure 3 9 Tie Down Points 01306 A A 007622 ...

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Page 41: ...quipment to operate safely and properly over a long period of time Never perform any routine service oil and oil filter changes cleaning etc unless all electrical components are shut off Before servicing the unit always follow the instructions listed below Verify the control power switch is turned OFF O Verify the circuit breakers are turned OFF O Activate push in the emergency stop switch Disconn...

Page 42: ...l supplied with the unit for more information Engine Oil Recommendations Contact a GMASD or refer to the applicable engine service manual for engine oil recommendations Coolant Recommendation Contact a GMASD or refer to the applicable engine service manual for engine coolant recommendations See table below for mixtures Freezing Point F C 34 36 62 52 84 64 Water Volume 50 40 30 Anitfreeze Volume 50...

Page 43: ...d of every 500 hours Basic Maintenance Schedule Isuzu Engine Item Daily First 50 Hr Break In Period Every 500 Hr Every 2 000 Hr As Required Check engine oil level Check engine coolant level Check fuel level Drain fuel filter Check tire pressure Check all electrical connections Clean battery Check fan ALD drive belt tension replace if necessary Inspect radiator fins for debris clean as required Pre...

Page 44: ...r fins for debris clean as required Check fuel filter water separator bowl Check air cleaner dust valve restriction indicator gauge 1 Perform Daily Walk Around Inspection Check oil vapor recirculation system non return value Change engine oil and replace oil filter 2 Replace oil vapor recirculation filter Service battery Replace fuel filter elements Check engine mounts Check air intake hoses conne...

Page 45: ...maintenance alarm reminder must be reset Proceed as follows to reset the maintenance alarms 1 With the unit shut down move the control power switch to CONTROL ON I The controller will toggle automatically to the home screen after initialization 2 Press or to enter the maintenance screens 3 Press and O simultaneously The next screen displays the Configuration menu 4 Press to move the cursor blue hi...

Page 46: ...t oil Top Wind Models Apply a lightweight oil to the screw stem Figure 4 1 Lubrication Points Trailer Wheel Bearings The trailer axles are equipped with a grease fitting to allow lubrication of the wheel bearings without needing to disassemble the axle hub To lubricate the axle bearings remove the small rubber plug on the grease cap attach a standard grease gun fitting to the grease fitting and pu...

Page 47: ...eck coolant level in radiator Add coolant if needed Inspect hoses for leaks Repair or replace as necessary Visually inspect for leaks Verify no coolant has mixed with the engine oil oil will appear milky See engine operator s manual for additional information High coolant temperature shutdown Low coolant level Blockage in radiator Leakage in coolant hoses engine block or water pump Add coolant if ...

Page 48: ...44 Owner s Manual for Mobile Generator Troubleshooting This page intentionally left blank ...

Page 49: ...TO GND BAR BN WT3 BN2 BN WT OR WT YL WT TO GND BAR TO GND BAR TO GND BAR BN WT3 BN2 GROUND STUD GROUND BAR TO GND BAR BAR GND BAR GND TO BK WT L3 L2 L1 YL WT LUG DOOR C NO HELD CLOSED NORMALLY OR WT1 PANEL INTERIOR LIGHT BK RD BK RD TO VREG BK RD BL BK RD BL WT YL PANEL LIGHT LUG LIGHT1 LUG LIGHT2 INTERIOR LIGHT2 OR WT3 BL YL 1 2 3 4 5 6 7 TB2 W V U T S R P N M E F A B G H J OR WT3 K C OR WT2 BN W...

Page 50: ...TO GND BAR TO GND BAR BN WT3 BN2 GROUND STUD GROUND BAR TO GND BAR BAR GND BAR GND TO BK WT L3 L2 L1 YL WT LUG DOOR C NO HELD CLOSED NORMALLY OR WT1 PANEL INTERIOR LIGHT RD BK RD BK RD BL BK RD BL WT YL PANEL LIGHT LUG LIGHT1 LUG LIGHT2 INTERIOR LIGHT2 OR WT3 BL YL 1 2 3 4 5 6 7 TB2 OR WT3 BL YL BK WT BK WT BL YL BL YL BK WT BK WT BK WT BK WT WT BN SWITCH 1 2 3 10 7 6 5 4 G 1 2 3 10 11 8 7 6 5 4 1...

Page 51: ...31 37 38 39 40 5 9 13 6 10 14 7 8 11 12 15 16 1 2 3 4 2 7 8 1 4 6 5 3 RD1 GN YL BN WT BL RD VOLT REGULATION RELAY 17 21 25 18 22 26 19 20 23 24 27 28 RD BK BK BLK TP0 WT WT WT BK RD BL WT YL W V U T S R P N M 1 2 3 4 5 6 7 TB2 E F A B G OR WT3 REMOTE BK WT DOOR C NO HELD CLOSED NORMALLY OR WT1 C LUG TO VREG H J BK RD BK RD 2 1 WT YL L3 L2 L1 REMOVE JUMPERS FOR 4 POSITION PHASE SWITCH 1 2 3 10 7 6 ...

Page 52: ...11 12 15 16 1 2 3 4 2 7 8 1 4 6 5 3 RD1 GN YL BN WT BL RD VOLT REGULATION RELAY 17 21 25 18 22 26 19 20 23 24 27 28 RD BK BK BLK TP0 BK RD BK RD 2 1 WT YL L3 L2 L1 REMOVE JUMPERS FOR 4 POSITION PHASE SWITCH 1 2 3 10 7 6 5 4 G BN2 BN WT3 1 2 4 3 RD1 RD BK G 11 8 12 9 BK WT LUG DOOR C NO HELD CLOSED NORMALLY OR WT1 PANEL INTERIOR LIGHT RD BK RD BL WT YL PANEL LIGHT LUG LIGHT1 LUG LIGHT2 INTERIOR LIG...

Page 53: ... G W Y 2 POS BLK L0 G GFCI2 20 GFCI1 20 G L0 BK RD BK RD BK RD BK RD WT GN YL WT WT GND STUD WT WT BK RD BK RD BK RD BK RD BK RD GN YL GN YL GN YL GN YL A B C D E 90582_ORG_08 18 14 90594_C_07 21 16 RECEPTACLE 68635 WHITE GREEN BLACK BREAKER 14432 TERMINAL 65003 50125 WHITE WHITE SPLICE 66080 SPLICE 66080 BLACK BLACK GREEN TERMINAL 65006 BLOCK HEATER 28407 ...

Page 54: ...E RELAY VOLTAGE RELAY TO 120V TO 120V BREAKERS BREAKERS WT WT RD RD BK BK BK BK WT WT BK BK BK BK BK BK BK BK BK BK BK BK WT WT BK BK RD RD BUCK BUCK XFMR XFMR X1 X1 X3 X3 X2 X2 X4 X4 H4 H4 H2 H2 H3 H3 H1 H1 3 POS BLK 3 POS BLK L0 L0 T7 T7 T9 T9 BRKR BRKR 20 20 BRKR BRKR 20 20 90583_ORG_08 18 14 PMG BN BN WT 1 2 3 4 5 6 7 TB2 REMOVE JUMPERS FOR PMG 1 90589_ORG_08 18 14 ...

Page 55: ...RD VI TO EXPANSION VI TO GND BAR BK SPARE TO GND BAR BATT FUSED FU SW 20A 20A 20A FUSE BLOCK RD BK4 RD WT RD WT RD OR RD WT RD WT RD WT 15A A B A B C D E F G H J I H G F E GY BL WT BN WT BN WT1 GY BK OR WT1 VI1 BK WT 1 2 3 4 TB1 VI2 IDLE SPEED BK WT GY BK BK WT WT RD WT RD BK WT SPARE GY BK FUEL RD VI RD VI WT VI WT RD BK WT SHLD CLR BK TO GND BAR BK WT TO GND BAR BK WT ENABLE FUEL XFER WT BK BK W...

Page 56: ...10 02 14 TRAILER PLUG GN BK YL BN WT LAMP MARKER AMBER WT WT AMBER MARKER LAMP BK WT RED MARKER LAMP BK BN LAMP PLATE LICENSE WT BK LAMP MARKER RED WT STOP TURN SIGNAL LAMP RIGHT LEFT SIGNAL LAMP STOP TURN WT BK RD WT RD BK WT GN BN WT BN BN WT BN WT YL BN WT RIGHT LEFT RIGHT LEFT ...

Page 57: ...Brakes BATTERY BREAKAWAY SWITCH BL WT BK BRAKE BRAKE BL BRAKE BRAKE WT TANDEM AXLE BRAKE BRAKE TRI AXLE SINGLE AXLE SPLICE SPLICE SPLICE SPLICE SPLICE SPLICE SPLICE SPLICE SPLICE SPLICE SPLICE SPLICE BL WT BL WT SPLICE BK BL WT SPLICE BL FRAME GND 90286_E_03 18 14 ...

Page 58: ...ring Diagrams 12 Volt Battery Charger Power Zone Low Oil Level If Equipped BATTERY 12 V BLK RED BATTERY CHARGER 66212 66212 WHITE GREEN BLACK RECEPTACLE 65285 BREAKER 15568 TERMINALS 65003 90593_B_09 19 16 LOW A B OIL LEVEL 90595_ORG_10 31 14 ...

Page 59: ......

Page 60: ...ights reserved Specifications are subject to change without notice No reproduction allowed in any form without prior written consent from Generac Mobile Products LLC Generac Mobile Products LLC 215 Power Drive Berlin WI 54923 GeneracMobileProducts com 800 926 9768 920 361 4442 ...

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