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Generac Power Systems MAGNUM MMG25IF4, Operating Manual

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Generac Power Systems MAGNUM MMG25IF4 Operating Manual Download Page 59

Wiring Diagrams

36949 B

MMG25I-35D-45I-55DF4 Operating Manual

53

DC WIRING

TO GND BAR

TO GND BAR

TO GND BAR

BAR

GND

TO

BK

CLR

SHLD

TO GND BAR

TO GND BAR

TO GND BAR

TO GND

BAR

BAR

GND

TO

LED

BOX

SWICH

PHASE

BAR

GND

TO

LED

TO GND BAR

TO GND BAR

BAR

GND

TO

BAR

GND

TO

1.  

T

O

 ADD OPTIONAL

 REMOTE 

ANNUNCIA

T

O

R (COMMUNICA

TIONS) 

FOR 

A

T

T

 GENERAC USE 

ANALOG EXP

A

NSION MODULE.

NOTES:

WT/VI

RD3

1

2

NC

LOW 

COOLANT

GY/BK

BK/WT

2

3

6

20

8

13

31

30

15

14

19

11

12

21

22

1

5

18

4

23

7

10

28

29

24

25

26

27

9

16

17

31 PIN

OPTIONAL

HEA

T

ED

FUEL

FA

N

OPTIONAL

CLUTCH

FIL

T

ER

GY/OR

BK/WT

FUEL

OPTIONAL

XFER

PWR

GND

VI/YL

BK/WT

CONN 2

PUMP

GY/OR

E-ST

OP

SWITCH

GY/BK

BK/WT

VI2

BK/WT

BK/WT

CLR

PHASE SW DOOR

50 Hz

LOW COOLANT

REMOTE STAR

T

FA

N CLUTCH

LUG DOOR

FUEL XFER ENABLE

SHUNT

 TRIP

FUEL TRANSFER

ALARM

RED BEACON

OIL LEVEL

RECONNECT DOOR

LEAK DETECT

BK

RD

BL

BN/WT

OR/WT

YL/WT

GN/YL

BK/WT

RD/VI

RD/YL

WT/VI

BK/WT

OR

GY/OR

GND

BAR

BK/WT

TO

RD/BK6

RD/BK7

CONTROL

POWER

SWITCH

RD/WT

RD/BK6

YL

GY/YL

BK

BK

CLR

SHLD

VI/YL

87

86

30

85

RD/YL

RD

ST

AR

T

RD1

RD1

87

87A

86

30

85

FA

N

CLUTCH

GY/YL

RD/VI

87

87A

86

30

85

RD/WT

FIL

TER

HEA

T

ED

RD/VI

BK

RD

RD/VI

T

O

 EXP

ANSION

VI

BK

AMB BEACON

OR/BK

OR/WT

OR/YL

BK/WT

BATT

FUSED

FU&SW

20A

20A

20A

FUSE

BLOCK

RD/BK4

POWER

T

O

 DISPLA

Y

RD/BK

RD/WT

RD/WT

RD

OR

RD3

RD/WT

RD/WT

OR/BK

OR/WT

OR/YL

T

O

 DISPLA

Y

RS485

RD/BK5

BK/WT

15A

AB

ABC

D

EF

G

H

I

J

K

J

I

H

G

F

E

GY/BL

WT/YL

WT

BN/WT

BN/WT1

WT

BK

GY/BK

OR/WT1

VI1

BK/WT

1

2

3

4

TB1

VI2

LEAK 

SWITCH

RECONNECT

DOOR

ALARM

RED

BEACON

AMBER

BEACON

OR/BK

OR/WT

OR/YL

BK/WT

1000RPM IDLE

BK/WT

GY

GY

BK/WT

GY/BK

FORCE REGEN

BK/WT

WT/RD

WT/RD

BK/WT

LOAD SHED

GY/BK

C

B

REMOTE

FUEL

RD/VI

RD

RD/VI

VI

WT/VI

BK/WT

WT/YL

BK/WT

RD/BK

RD/BK2

WT/RD

BK/WT

GY

BK/WT

BK

CLR

SHLD

BK/WT

BK/WT

CN

O

(HELD

CLOSED

ENABLE

FUEL

 XFER

WT/BK

BK/WT

87

87A

86

30

85

XFER

RD4

BK/WT

GY/OR

FUEL

K1

50Hz

LOW 

A

B

X

T

C

A

W

M

N

P

R

S

H

J

K

L

U

E

B

V

D

F

G

21 PIN CONN1

FUEL

A

RD/BK

RD/BK

VI/WT

VI/WT

PH SW DOOR

CN

O

(HELD

CLOSED

NORMALL

Y

)

BK/WT

BK/WT

TO

 EXPANSION

VI

VI1

BK/WT

RD/BK3

GND

BAR

BK/WT

TO

12V

15A

5

15A

6

GND

BAR

TO

PM600

VOL

T

AGE

T7

T9

F-

F+

P2

P1

REGULA

T

O

R

B

A

MODULE

BK/WT

WT/YL

MODULES

INTERIOR

LIGHT1

OR/WT2

IDLE 

SWITCH

BL/YL

GN/YL

GY/RD

RD/BK2

RD/BK1

RUN

GND

RD/VI

BK/WT

TELEMETR

Y

BN

BN/WT2

BN1

WT 
BK

WT

BK

BK/WT

WT/BL

PLUG

TO

G

E

T

H

E

R

WHEN OPT NOT

 USED

C

B

BL/YL

BK

WT

PLUG

TO

G

E

T

H

E

R

WHEN OPT NOT

 USED

OIL

DETECT

OPTIONAL

LEVEL

OPTIONAL

FUEL LEVEL

NORMALL

Y)

CAN-LOW

CAN-HIGH

150W MAX

OPTIONAL

HEA

T

ED

FUEL FIL

T

ER

VI1

BK/WT

150W MAX

BK/WT

VI

VI1

RD

5

6

5

6

5

6

6

5

ALARM

SPLICE

WT

BK

BN/WT1

BN1

OR/WT1

GY/OR

OR/WT2

BN/WT2

BN

BK

RD

BK/WT

GND

BAR

TO

WT

BL

RD

BK

YL

GN/YL

YL/WT

OR/WT

BN/WT

RD2

RD2

RD2

CHG AL

T

BA

TT

 NEG

ST

AR

T

BA

TT

 POS SW

FUEL

BA

TTER

Y

 CONST

A

NT

FORCE

REGEN

BK/WT

5

6

GY/GN

MODULE 7740

CHRG ALT

MPU

FUEL LEVEL

 (FLEXIBLE)

BA

TTER

Y

+VE

-VE

OIL PRESSURE

1

1

 INPUTS

FUEL

CRANK

COMMON GROUND

WA

TER TEMP

CLOSE

GEN

D

OUTPUT

AUX FUEL T

ANK SENDER

C

OUTPUT

FLEXIBLE IF

J1939 IS USED

SCR

46

45

44

43

41

42

39

24

23

22

67

66

65

64

63

62

61

60

19

18

17

16

15

6

5

4

3

1

2

GEN VOL

TS

W

V

U

N

SCR

B

A

RS232

L3

L2

L1

RS485

V1

+VE

6 FET

 OUTPUTS

GOVERNOR

AV

R

O/P

O/P

L

H

SCR

ENGINE ECU

MSC

SCR

H

L

+

SCR

56

40

30

29

28

57

50

49

48

47

69

68

7

11

10

9

83

8

37

36

35

34

27

26

25

32

31

33

BA

A

B

12

13

BUS VOL

T

S

N

ST

R

POR

T

PROGRAMMING

USB

L2

L3

L1

70

USB HOST

RJ45

ETHERNET

S2

S1

L1 LOAD

CURRENT 8660 ONL

Y

V2

COM

CT4

L3S1

L2S1

GEN CURRENT

L1S1

CT1

CT2

C

T3

NS1

54

55

53

52

51

M

N

P

R

S

T

U

V

W

A

B

C

D

E

F

G

H

J

K

L

90540_D_06.15.15

Summary of Contents for MAGNUM MMG25IF4

Page 1: ...OPERATING MANUAL Parts manuals available online at www generacmobile com 36949 B 02 16 01306 DIESEL GENERATOR MMG25IF4 MMG35DF4 With Controller TM MMG45IF4 MMG55DF4 ...

Page 2: ...ARNING 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 000005 WARNING ENVIRONMENTAL HAZARD Always recycle batteries at an official recycling center in accordance with all local laws and regulations Failure to do so could result in environmental damage death or serious injury 000228...

Page 3: ...plication other than for which it was designed Only a trained and licensed electrician should perform wiring and connections to unit Wiring must be in compliance with National Electrical Code NEC state and local regulations as well as Occupational Safety and Health Administration OSHA guidelines GENERAC MOBILE PRODUCTS LLC 215 Power Drive Berlin WI 54923 U S A Phone 920 361 4442 FAX 920 361 4416 T...

Page 4: ...iv This Page Intentionally Left Blank ...

Page 5: ...oners 22 Section 3 Operation Prestart Checklist 23 Manual Starting of the Unit 23 Auto Remote Starting of the Unit 24 Derating for Altitude 25 Generator Output Connection Lugs 25 Fine Voltage Adjustment 26 Voltage Selector Switch 27 Voltage Regulation 28 Customer Convenience Receptacles 28 Main Circuit Breaker 29 Exhaust Filter Cleaning Operations 30 Disable Automatic Auto Exhaust Filter Cleaning ...

Page 6: ...utdown 45 Low Oil Pressure Shutdown 45 Low Coolant Level Shutdown 45 High Coolant Temperature Shutdown 45 Section 6 Wiring Diagrams AC Wiring MMG25IF4 MMG45IF4 47 AC Wiring MMG35DF4 MMG55DF4 48 AC Wiring 4 Pos Voltage Selector Switch Option MMG25IF4 MMG45IF4 49 AC Wiring 4 Pos Voltage Selector Switch Option MMG35DF4 MMG55DF4 50 AC Wiring Option Standard Receptacles 51 AC Wiring Option Engine Heate...

Page 7: ...d understand all of the instructions This equipment was designed for specific applications DO NOT modify or use this equipment for any application other than which it was designed for Equipment operated improperly or by untrained personnel can be dangerous Read the operating instructions and familiarize yourself with the location and proper use of all instruments andcontrols Inexperiencedoperators...

Page 8: ...lesh or eat holes in clothing Protective eye wear and clothing are necessary when working on or around the battery Always disconnect the negative battery cable from the corresponding terminal before performing any service on the engine or other components DO NOT open the radiator cap or oil drain plug while the engine is running or before the engine has cooled down Pressurized coolant and hot engi...

Page 9: ... the coupler clean and apply fresh grease each time the trailer is towed to eliminate squeaking Connect safety chains in a crossing pattern under the tongue and ATTACH THE BREAKAWAY CABLE TO THE REAR BUMPER OF THE TOWING VEHICLE Do not attach the cable to the trailer hitch Before towing the trailer verify that the weight of the trailer is equal across all tires On trailers with adjustable height h...

Page 10: ...P Hot surface s nearby Unit electrical ground Anchor tie down point Stop engine Dangerous voltage may be present Asphyxiation hazard operate in well ventilat ed area Fan hazard keep body parts clear of this area Belt entanglement hazard keep body parts clear of this area Safety alert symbol used to alert you to potential hazards Read and understand the operator s manual before operating Disconnect...

Page 11: ...rime kW kVA 22 22 Amps 1Ø Prime 240V A 92 Frequency Hz 60 Power Factor 1 1Ø 0 8 3Ø Sound dB A 23 ft prime 66 Weights Dry Weight Skid Mounted lbs kg 2430 1102 Operating Weight Skid Mounted lbs kg 3160 1433 Dry Weight Trailer Mounted lbs kg 2950 1338 Operating Weight Trailer Mounted lbs kg 3680 1669 Standard trailer only Consult factory for custom trailer weights Capacities Fuel Tank Volume gal L 10...

Page 12: ...27 27 Amps 1Ø Prime 240V A 113 Frequency Hz 60 Power Factor 1 1Ø 0 8 3Ø Sound dB A 23 ft prime 68 Weights Dry Weight Skid Mounted lbs kg 3125 1418 Operating Weight Skid Mounted lbs kg 3860 1751 Dry Weight Trailer Mounted lbs kg 3725 1690 Operating Weight Trailer Mounted lbs kg 4460 2023 Standard trailer only Consult factory for custom trailer weights Capacities Fuel Tank Volume gal L 100 379 Usabl...

Page 13: ... 33 33 Amps 1Ø Prime 240V A 138 Frequency Hz 60 Power Factor 1 1Ø 0 8 3Ø Sound dB A 23 ft prime 66 Weights Dry Weight Skid Mounted lbs kg 2843 1290 Operating Weight Skid Mounted lbs kg 3580 1624 Dry Weight Trailer Mounted lbs kg 3363 1525 Operating Weight Trailer Mounted lbs kg 4100 1860 Standard trailer only Consult factory for custom trailer weights Capacities Fuel Tank Volume gal L 100 379 Usab...

Page 14: ...42 42 Amps 1Ø Prime 240V A 175 Frequency Hz 60 Power Factor 1 1Ø 0 8 3Ø Sound dB A 23 ft prime 68 Weights Dry Weight Skid Mounted lbs kg 3305 1499 Operating Weight Skid Mounted lbs kg 4040 1833 Dry Weight Trailer Mounted lbs kg 3905 1771 Operating Weight Trailer Mounted lbs kg 4640 2105 Standard trailer only Consult factory for custom trailer weights Capacities Fuel Tank Volume gal L 100 379 Usabl...

Page 15: ...s Figure 2 1 Unit Dimensions Specifications are subject to change without notice A Width B Length C Height MMG25IF4 35DF4 45IF4 55DF4 Skid Mounted 39 in 99 m 95 in 2 41 m 65 in 1 65 m MMG25IF4 35DF4 45IF4 55DF4 Trailer Mounted 58 in 1 45 m 152 in 3 81 m 83 in 2 11 m 01906 C C B A A B ...

Page 16: ...TRAILER MODEL XXX000 GAWR PNBE TIRE PNEU RIM JANTE GONF A FROID KPA PSI LPC SGL DUAL EACH AXLE THIS VEHICLE CONFORMS TO ALL APPLICABLE STANDARDS PRESCRIBED UNDER THE U S FEDERAL MOTOR VEHICLE SAFETY STANDARDS FMVSS AND CANADIAN MOTOR VEHICLE SAFETY REGULATIONS IN EFFECT ON THE DATE OF MANUFACTURE CE VEHICULE EST CONFORME A TOUTES LES NORMES QUI LUI SONT APPLICABLES EN VERTU DU REGLEMENT SUR LA SEC...

Page 17: ... 1 Engine exhaust 8 Lug box panel access 2 Radiator access panel 9 Containment drain fuel drain port 3 Central lift point 10 Receptacle panel 4 Fuel fill 11 Emergency stop 5 Engine and battery access 12 Control access panel 6 Radiator drain port 13 Breaker panel access 7 Engine access 01880 1 3 4 7 9 8 10 11 12 2 6 5 13 ...

Page 18: ...rating Manual 36949 B CONTROL PANEL Figure 2 4 Control Panel Rear of Unit 1 Voltage selector switch 4 Engine idle switch 2 50 60 Hz switch optional 5 Control power switch 3 Fuel transfer pump switch optional 6 Power Zone controller 1 3 6 4 2 5 01881 ...

Page 19: ...k connection lugs 5 optional 3 50A circuit breakers 3 11 Connection for optional equipment inlet 4 Service lights switch 12 120V 240V twist lock receptacles 3 5 20A circuit breakers 2 13 Connection for battery charger 6 Lug door safety switch 14 120V GFCI receptacles 2 7 Remote start terminal block 15 Emergency stop switch 8 Ground connection lug 1 2 3 4 5 6 8 9 10 12 13 14 15 01882 7 2 11 ...

Page 20: ...ler also records a history of unit performance which may be viewed at any time and will not be lost when the controller is powered down Figure 2 6 Power Zone Gen Controller Layout Controller Features and Functions Operator Screens These buttons are used to enter the various operator screens from any other screen The operator screens consists of four screens Home Engine Generator and Voltage Adjust...

Page 21: ...oller into Stop mode whether in Manual mode or Auto mode CAUTION In case of an emergency press the emergency stop switch located on the side of the unit to stop the engine immediately The Engine Stop Reset O button may delay the engine shutdown if stop faults exist To prevent damage to the generator and connected equipment remove all loads from the generator by opening all circuit breakers turn OF...

Page 22: ...9 kPa Normal operating pressure is between 35 80 psi 241 552 kPa Coolant Temp Displays engine coolant temperature Current coolant temperature is displayed directly below the gauge at all times The gauge displays coolant temperature between 150 250 F 66 121 C Normal operating temperature of the unit is between 180 200 F 82 93 C with an average ambient air temperature of 70 F 21 C Battery Displays t...

Page 23: ... the AC output amperage produced by the generator in Amps A Additional information can be found on the electric power table at the bottom left side of the screen This provides an overview of all three lines and average voltage and amperage readouts Voltage Adjust Screen The Voltage Adjust screen displays the line to neutral and line to line voltage averages The operator can electron ically adjust ...

Page 24: ...r engine air inlet temperature charge alternator oil pressure fuel level battery voltage coolant temperature and ECU lamp Note The content may change depending upon the selected engine and the features supported by the engine Figure 2 12 Engine Tab Screen Generator Tab The Generator tab contains maintenance and instrumentation data gathered from the generator Each page highlights different data ga...

Page 25: ...tails Table 1 Possible Alarm Types Alarm Type Color Background Text Graphic Warning Yellow Black Electrical Trip Purple Black Shutdown Red Black ECU Code Blue White 00399 GEN V SITE GENSET 7741 7740 07 10 480V 277V 3 Phase Return Delay 10 00 00 0 0 Hz Total Generator kWh kVAh kVArh kW kVA kVAr pf 0 0 0 0 0 0 0 0 0 0 0 0 0 00 0 0 0 0 kW kVAr Status Schedule I O Alarms Engine Generator 1 9 L1 L2 L2 ...

Page 26: ... kVA kVAr pf 0 0 0 0 0 0 0 0 0 0 0 0 0 00 0 0 0 0 kW kVAr Status Schedule I O Alarms Engine Generator 2 2 Warning Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown This is an event index 1 This is an event index 2 This is an event index 3 This is an event index 4 This is an event index 5 This is an event index 6 This is an event index 7 Thi...

Page 27: ... kW kVA kVAr pf 0 0 0 0 0 0 0 0 0 0 0 0 0 00 0 0 0 0 kW kVAr Status Schedule I O Alarms Engine Generator 1 1 Warning Warning Warning Action Description Alarm Hours Date Time Maintenance Scheduler Enabled to run Reserved Reserved Event Week Day Start Stop Duration Event Week Day Start Stop Duration 250 hr Maint Refer to Manual 500 hr Maint Refer to Manual 3000 hr Maint Refer to Manual 1 250 00 2 50...

Page 28: ...se 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: ...fuel levels For more information see General Maintenance Check engine fan belt tension and condition Check engine fan belt guard Check engine exhaust system for loose or rusted components Check radiator and surrounding shroud for debris Check to make sure none of the generator covers are loose or missing Verify all maintenance procedures are up to date For more information see General Maintenance ...

Page 30: ...e steps on some of the larger models 7 Once the engine starts it will immediately begin speeding up to a constant 1800 rpm The engine may hunt or change speeds until operating speed is reached After a few minutes of operation the engine will be warmed up and the operator screens will show engine and generator operating parameters 8 Check the generator for excessive noise or vibration and any coola...

Page 31: ...l Figure 3 3 Remote Start Terminal Block Before entering Auto mode verify the contacts on any remote switch linked to the unit are OPEN If the contacts on a remote switch are closed the engine will crank and start when Auto mode is entered Attach the switch leads to the two unused terminals on the unit s remote start terminal block For additional information refer to Auto Remote Starting of the Un...

Page 32: ...A ground connection is located next to the connection lugs The unit MUST be connected to ground for proper operating safety The generator neutral is bonded to ground when it is shipped from the factory The bonding plate will need to 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 ...

Page 33: ... through the lockout hole s By locking the handle in place unauthorized changing of the voltage setting is prevented L1 L2 208V L1 N 120V N L2 L3 208V L2 N 120V L3 L1 208V L3 N 120V VOLTAGES AT RECEPTACLES 120 208V 3 PHASE Switch styles vary by model RECEPTACLE L L L N GFCI 120V GFCI w Buck 120V Twist locks 208V 120V 277 480V 120 208V 120 240V 00085 VOLTAGES AT RECEPTACLES 277 480V 3 PHASE Switch ...

Page 34: ...thaMarathonDVR2000E digitalvoltageregulator pleaserefertotheMarathonoperating manual provided with the unit CUSTOMER CONVENIENCE RECEPTACLES The unit is equipped with five receptacles The large receptacles are 240 120VAC twist lock receptacles rated at 50A each The smaller duplex receptacles are 120VAC rated at 20A each with ground fault circuit interrupt GFCI protection These receptacles are not ...

Page 35: ...end using the receptacles in the 480V position When the voltage selector switch is in position for 208 120V 3Ø voltage at the three twist lock receptacles and the two GFCI receptacles is 208 120 volts MAIN CIRCUIT BREAKER The main circuit breaker is located on the main control panel When the breaker is OFF O power is interrupted between the connection lugs the optional cam lock receptacles and the...

Page 36: ... cleaning should be clear of any people and objects Exhaust gases and compo nents can reach temperatures hot enough to ignite and melt common materials Note Always park the unit in a safe location for elevated exhaust temperatures and check for adequate fuel level before beginning the exhaust filter cleaning process The cleaning cycle can take an extended period of time approximately 45 minutes Cl...

Page 37: ...longer displays DPF Regen Inhibit above the kW meter and the load used gauge TRANSFER SWITCH The generator neutral is bonded to ground when shipped from the factory The bonding plate will need to be removed when the unit is used as a standby power supply Installation should be in compliance with the National Electrical Code NEC state and local regulations When the unit is used as a standby power s...

Page 38: ...g the unit as a standby or substitute power supply make sure the output voltage and phase rotation of the generator match those of the local power utility Improper voltage or phase rotation may cause equipment damage or malfunction AUTO EXERCISE TIMER The Power Zone controller is capable of starting and stopping the unit automatically based on a programmable schedule Units installed in a standby a...

Page 39: ...d hold the Auto Manual Mode button for five seconds or until Auto mode is displayed at the top of the screen Note If any of the scheduled time slots are currently active the controller will begin the starting sequence and start the unit provided there are no shutdown conditions present SHUTTING DOWN THE UNIT Prior to shutting down the unit check with personnel using power supplied by the generator...

Page 40: ...o power down the unit under normal operating circumstances Doing so will result in equipment damage 000246 IDLE SWITCH MMG25I 45I ONLY The idle speed is 1000 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 1800 rpm if the idle switch is off Otherwise the unit will conti...

Page 41: ... 81 Nm d Third pass tighten to 90 120 ft lbs 122 162 Nm Note After the first road use re torque the lug nuts in sequence Figure 3 11 Lug Sequence 7 Maximum recommended speed for highway towing is 45 mph 72 km h Recommended off road towing speed is not to exceed 10 mph 16 km h LIFTING THE UNIT A central lift point is located on the top of the unit The central lift point is connected to a lift struc...

Page 42: ...Operation 36 MMG25I 35D 45I 55DF4 Operating Manual 36949 B This Page Intentionally Left Blank ...

Page 43: ... are necessary NEVER perform routine service 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 Disconnect the negative terminal on the battery Attach a Do Not Start s...

Page 44: ...oil level is below the add mark on the dipstick 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 Check the fuel level If the unit is connected to a remote start or transfer switch make sure the remote switch...

Page 45: ... or fuel quality is questioned replace every 250 hours instead of every 500 hours Item Daily First 50 Hours Break In Period Every 250 Hours Every 500 Hours Every 2000 Hours Check Oil Level Check Coolant Level Check Fuel Level Drain Fuel Filter Check Tire Pressure Check All Electrical Connections Clean Battery Check Fan Belt Tension Replace If Necessary Inspect Radiator Fins for Debris Clean as Req...

Page 46: ...ck Oil Level Check Coolant Level Check Fuel Level Check Tire Pressure Check All Electrical Connections Inspect Radiator Fins For Debris Clean As Required Check Fuel Filter Water Separator Bowl Check Air Cleaner Dust Valve Restriction Indi cator Gauge 1 Perform Visual Walkaround Inspection Check Oil Vapor Recirculation System Non Return Valve Change Engine Oil and Replace Oil Filter 2 Replace Oil V...

Page 47: ...il from the factory Extra care during the first 100 hours of engine operation will result in better performance and longer engine life DO NOT exceed 100 hours of operation with the break in oil Operate the engine at heavy loads 60 90 of maximum as much as possible If the engine has spent significant time at idle constant speed s and or light load or if makeup oil is required a longer break in peri...

Page 48: ...equipment CAUTION Do not remove ash by using water or other chemicals Removing ash by these methods may cause equipment damage and create unsafe operating conditions CAUTION Only a qualified service provider should remove handle and dispose of DPF ash These materials may be considered hazardous under federal state and local regulations and must be handled and disposed of properly To avoid unnecess...

Page 49: ...ith the same lightweight oil Top Wind Models Apply a lightweight oil to the screw stem Figure 4 1 Lubrication Points TRAILER WHEEL BEARINGS Some trailers are equipped with a grease zerk fitting to allow lubrication of the wheel bearings without the need 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 ...

Page 50: ...Maintenance 44 MMG25I 35D 45I 55DF4 Operating Manual 36949 B This Page Intentionally Left Blank ...

Page 51: ... psi 138 kPa Add oil if required 2 Visually inspect engine for oil leaks 3 If oil level is good restart the unit and verify the loss of oil pressure Shut the engine down immediately if the oil pressure value does not read 5 psi 34 kPa within five seconds 4 Check oil pressure sender To identify corrective action see the troubleshooting section of the engine oper ator s manual Low Coolant Level Shut...

Page 52: ...Troubleshooting 46 MMG25I 35D 45I 55DF4 Operating Manual 36949 B This Page Intentionally Left Blank ...

Page 53: ...GN YL LED 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 O...

Page 54: ...O 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 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...

Page 55: ...LK BLK 34 33 29 30 36 35 32 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 POSITIO...

Page 56: ...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 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 LI...

Page 57: ...GINE HEATER 3 POS BLK L0 T7 T9 X G W Y BRKR 50 BRKR 20 BRKR 20 BRKR 50 BRKR 50 X G W Y X 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 BK WT GN EDISON PLUG ENGINE HEATER 90594_ORG_10 29 14 ...

Page 58: ... 8 7 2 VOLTAGE 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 59: ...OTE FUEL RD VI RD RD VI VI WT VI BK WT WT YL BK WT RD BK RD BK2 WT RD BK WT GY BK WT BK CLR SHLD BK WT BK WT C NO HELD CLOSED ENABLE FUEL XFER WT BK BK WT 87 87A 86 30 85 XFER RD4 BK WT GY OR FUEL K1 50Hz LOW A B X T C A W M N P R S H J K L U E B V D F G 21 PIN CONN1 FUEL A RD BK RD BK VI WT VI WT PH SW DOOR C NO HELD CLOSED NORMALLY BK WT BK WT TO EXPANSION VI VI1 BK WT RD BK3 GND BAR BK WT TO 12...

Page 60: ...0584_ORG_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 61: ... ELECTRIC BRAKE OPTION 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 62: ...D 45I 55DF4 Operating Manual 36949 B DC WIRING OPTION 12V BATTERY CHARGER DC WIRING OPTION LOW OIL LEVEL EDISON PLUG 16 3 BRN BLU YEL GRN BATTERY CHARGER BATTERY 12 V BLK RED 90593_ORG_10 29 14 LOW A B OIL LEVEL 90595_ORG_10 31 14 ...

Page 63: ...nerator connection lugs DANGER IMPROPERORINCORRECTCONNECTIONSTOABUILDING SELECTRICALSYSTEM CAN CAUSE POTENTIALLY LETHAL VOLTAGE TO BACKFEED INTO UTILITY LINES THIS MAYRESULT IN INJURYOR ELECTROCUTION TO UTILITYWORKERS NEARBY MAKE SURE THE GENERATOR IS SUPPLYING POWER TO AN ISOLATED OBJECT OR BUILDING THAT IS NOT CONNECTED TO ANY UTILITY LINES Connections should be made by plugging power cables equ...

Page 64: ...her speeds increasing cooling system efficiency The cooling fan will engage at full speed when the coolant temperature rises When the fan is operating at full speed it will switch to a slower speed when the coolant temperature drops There will be an audible difference when the engine cooling fan switches speeds Depending on unit model the temperature ranges vary between 170 F and 200 F 77 C and 93...

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