Generac Power Systems MDG25IF4 Page 58 Owner'S Manual Download

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Owner’s Manual for Mobile Generator

Wiring Diagrams

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Summary of Contents for MDG25IF4

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

Page 2: ...peration 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...

Page 3: ...nually Starting the Unit 25 AUTO Remote Starting the Unit 26 Wet Stacking 26 Low Idle Switch 27 Cold Weather Operation 27 Using a Booster Battery or Charger if equipped 28 Parallel 28 Generator Output...

Page 4: ...enerator Section 5 Troubleshooting General Troubleshooting 41 Section 6 Wiring Diagrams Controls 43 Control Box 1 of 2 44 Control Box 2 of 2 45 Generator Cabin 1 of 2 46 Generator Cabin 2 of 2 47 Gene...

Page 5: ...s service find service When contacting a GMP ASD 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...

Page 6: ...uipment 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...

Page 7: ...s 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...

Page 8: ...ut Equipment connected to the unit overheats Sparking occurs Engine misfires or there is excessive engine generator vibration Protective covers are loose or missing Ambient air temperature is above 12...

Page 9: ...e trailer tongue to keep the trailer as level as possi ble Safe Towing Techniques Practice turning stopping and backing up in an area away from heavy traffic prior to transporting the unit Maximum rec...

Page 10: ...inal lugs 2 Coolant drain 17 Terminal connections voltage selector switch 3 Tie down point 18 Electrical ground 4 Engine oil drain 19 Starting and stopping the generator 5 Do not open door with engine...

Page 11: ...Owner s Manual for Mobile Generator 7 Introduction and Safety Figure 1 1 Exterior Decals Inside door on plexi glass panel 007607 9 1 7 8 10 4 3 2 5 6 3 3...

Page 12: ...2 L3 240V L2 N 208V L3 L1 240V L3 N 120V N 120 240V 3PH 277 480V 120 208V 120 240V 1PH 120 240V 3 PHASE 120 240 V 3 277 480 V 120 208 V 120 240 V 1 480 277 208 120 277 480V 3 PHASE 120 208V 3 PHASE 12...

Page 13: ...ULLLEITER L0 AM RAHMEN ANGESCHLOSSEN NEUTRO L0 CONECTADO AL BASTIDOR POSITION NEUTRE L0 LORSQUE FIX AU CADRE Backside of control panel access door ATTENTION ATENCI N VORSICHT CAUTION 120V GFCI recepta...

Page 14: ...10 Owner s Manual for Mobile Generator Introduction and Safety This page intentionally left blank...

Page 15: ...4 4 16 7 Oil Crankcase qt L 10 9 10 4 10 9 10 4 10 9 10 4 Generator Make Model Marathon Electric 282PSL1705 SUPERSTART Marathon Electric 283PSL1707 VFLEX Marathon Elec tric 283PSL28106 Insulation Cla...

Page 16: ...ted Dry lb kg 2 247 1 019 2 318 1 051 2 288 1 038 Trailer Mounted Operating lb kg 2 771 1 256 2 842 1 289 2 812 1 275 Specifications are subject to change without notice Power rating achieved through...

Page 17: ...ance Figure 2 2 Unit and Serial Number Locations Altitude and Temperature Limitations All units are subject to derating for altitude and temperature Derating reduces the available power for operating...

Page 18: ...door E Fuel fill port Q Breaker and connection panel access door F Tie down point 4 locations R Emergency stop switch G Generator access door S Stabilizer jack 2 locations if equipped H Engine access...

Page 19: ...ped L Primary fuel filter C Generator phase switch M Coolant overflow container D VFLEX switch if equipped N Battery disconnect switch E Generator O Engine oil filter F Air filter P Connection panel G...

Page 20: ...Panel Figure 2 5 Connection Panel A Main circuit breaker E Connection lug 5 locations B Panel light F Safety shutoff switch C Service lights switch G Cam lock receptacle 5 locations if equipped D Neu...

Page 21: ...ceptacle Panel A 50 A circuit breaker 3 locations E LED light switch B 20 A circuit breaker 2 locations F 120 240 V twist lock receptacle 3 locations C Block heater power supply if equipped G Battery...

Page 22: ...tion Control Panel Figure 2 7 Control Panel A Genset controller E Fuel transfer pump switch B Door latch F Interior cabin lights switch C Voltage adjustment dial potentiometer G Low idle switch D not...

Page 23: ...ndition or load demand Figure 2 8 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 eq...

Page 24: ...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 T...

Page 25: ...ions 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...

Page 26: ...e problems When loading generator observe the load amperage on each line Alarms Page Figure 2 12 Alarm Page The Alarms page displays active warnings and active alarms including engine DTCs ECU DTC Pag...

Page 27: ...ure 2 17 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 Fig...

Page 28: ...a lockout mechanism When engaged the switch is locked in place preventing configuration changes See Using the Voltage Selector Switch for instructions on switching the voltage NOTE See Using the Volta...

Page 29: ...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 tempera...

Page 30: ...engine and generator are operating correctly 2 To check the remote start circuit remove the wires from the remote start terminal block Press the AUTO button and the display screen will show auto mode...

Page 31: ...ave improved flow at low temperatures NOTE Contact a GMASD or refer to the applicable engine service manual for more information The oil pan heater crankcase ventilation CCV heater and fuel filter hea...

Page 32: ...oor 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 a...

Page 33: ...l 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 devic...

Page 34: ...ailable any time the generator is running even if the main circuit breaker is OFF O Verify equipment connected to the receptacles is turned OFF before turning the breakers ON I NOTE When the voltage s...

Page 35: ...to a power supply normally serviced by a utility company notify the utility company and check state and local regulations Familiarize yourself with all instructions and warning labels supplied with t...

Page 36: ...op fail alarm will be displayed on the display screen 4 After the unit shuts down wait two minutes after engine shutdown for controller actuated actions to complete and then set the control power swit...

Page 37: ...ngine should be inspected prior to a restart to verify if permanent damage or catastrophic failure has occurred If the unit is equipped with a PAS a test function has also been incorporated into the c...

Page 38: ...km h depending on the terrain Lifting the Unit 1 Verify the equipment being used to lift the unit is in good condition and has sufficient capacity For approximate weights see Specifications 2 Close an...

Page 39: ...int Attach slings chains or hooks directly to the central lift point A NOTE This unit is not equipped with forklift pockets Tying Down the Unit When securing the unit for transportation verify the equ...

Page 40: ...36 Owner s Manual for Mobile Generator Operation This page intentionally left blank...

Page 41: ...ty hazard Periodic maintenance and occasional repairs are necessary in order for the equipment to operate safely and properly over a long period of time Never perform any routine service oil and oil f...

Page 42: ...pplicable engine service manual for more information Figure 4 1 Engine Oil Viscosity Recommendations Figure 4 2 Engine Oil Grade Recommendations Coolant Recommendation Contact a GMASD or refer to the...

Page 43: ...erator Drive Plate Torque 1 Disconnect battery 2 Remove generator fan guard 3 Tighten each of the drive plate bolts to 27 ft lbs 36 Nm 4 Install generator fan guard 5 Connect battery ALD System Mainte...

Page 44: ...ack near the crank Rotate the jack handle to distribute the grease evenly A lightweight oil must be applied to the handle unit at both sides of the tube If equipped the axle bolt and nut assembly of t...

Page 45: ...ion Low coolant level shutdown Low coolant level Coolant hoses leaking Engine block or water pump leaking Allow engine to cool then check coolant level in radiator Add cool ant if needed Inspect hoses...

Page 46: ...42 Owner s Manual for Mobile Generator Troubleshooting This page intentionally left blank...

Page 47: ...obile Generator 43 Section 6 Wiring Diagrams Controls COMPONENTS FOUND IN CONTROL BOX J2 J3 J4 J5 J6 J7 MC MC J1 EM1 EM1 EM1 GROUP G WIRING DIAGRAM MDG25IF4 STD3 DRAWING A0000430348 REVISION B DATE 4...

Page 48: ...ng Diagrams Control Box 1 of 2 CPS LIS MLS FTS ATS FB1 ECUWS STR DCHR FTR CBL GND2 TB1 PASR COMPONENTS FOUND IN CONTROL BOX FB1 VR TB7 ALDR POT VR GROUP G WIRING DIAGRAM MDG25IF4 STD3 DRAWING A0000430...

Page 49: ...r 45 Wiring Diagrams Control Box 2 of 2 CONN1R CONN1P CONN2R CONN2P CONN3R CONN3P CONN7P CONN4P CONN4R COMPONENTS FOUND ON THE CONTROL BOX GROUP G WIRING DIAGRAM MDG25IF4 STD3 DRAWING A0000430348 REVI...

Page 50: ...nerator Cabin 1 of 2 CCPS FLS1 CLS ES COMPONENTS FOUND IN GENERATOR CABIN CLS1 GND1 CONN5P CONN6P SM BD BATT GENERATOR FLS CLC1 CLC2 CL2 CRLC CRL CL1 CRLS CRLC1 GROUP G WIRING DIAGRAM MDG25IF4 STD3 DR...

Page 51: ...O N L I V R E HFF HFF 1 OVR 12VDC OVR1 FLD FLD1 SBC TMP TCR TCP TM LOG PASM FTP AB RB SBC1 SIREN COMPONENTS FOUND IN GENERATOR CABIN TELEMETRY 50W 12VDC W E O N L I V R E HFF 2 ALDC ALDC1 ALD PAS GRO...

Page 52: ...Diagrams Generator Box VFLEX If Equipped CT1 VFS CAP CONN5R CT2 CT3 CT4 VFLEX COMPONENTS COMPONENTS LOCATED IN GENERATOR BOX GEN GND PSAS VFB1 VFB2 GROUP G WIRING DIAGRAM MDG25IF4 STD3 DRAWING A00004...

Page 53: ...iagrams RSTB TB2 COMPONENTS LOCATED INSIDE CUSTOMER CONNECTION PANEL LDS CCLS CONN6R GND3 MLCB ST GS TB6 BL TB2 VFVRR VFVRR 4PVRR 4PVRR B C B A A C TB2 GROUP G WIRING DIAGRAM MDG25IF4 STD3 DRAWING A00...

Page 54: ...ing Diagrams PS 4 POSITION Y YY Z D COMPONENTS LOCATED IN GENERATOR BOX PS 3 POSITION Y YY Z COMPONENTS LOCATED IN GENERATOR BOX FRONT PSAS FRONT GROUP G WIRING DIAGRAM MDG25IF4 STD3 DRAWING A00004303...

Page 55: ...ator 51 Wiring Diagrams BTR PR BT GFCI1 TLO1 TLB1 GFCIB1 TB3 TLB2 TLB3 TLO2 TLO3 GND4 GFCIB2 GFCI2 COMPONENTS LOCATED IN GENERATOR BOX GROUP G WIRING DIAGRAM MDG25IF4 STD3 DRAWING A0000430348 REVISION...

Page 56: ...PHILLIPS TEMRO BH ASM2 ASM1 RSM1 RSM2 LPL TL1 TL2 TLC BAS TBC GND5 EB1 EB2 BCR TAH COMPONENTS LOCATED IN GENERATOR CABIN COMPONENTS LOCATED ON TRAILER AND TONGUE BC EBB OPH GROUP G WIRING DIAGRAM MDG2...

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Page 60: ...ghts 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 Pow...

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