Generac MCG1000 Operating instructions

Brand: Generac

Model: MCG1000

Category: Power generators

Type: Operating instructions

OPERATING MANUAL

Parts manuals available online at www.generacmobile.com

37789 ORG 08/15

01857

DIESEL GENERATOR

MCG1000MT2

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.

iii

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. Additional copies are available from

Generac Mobile Products, or can be found at www.generacmobile.com.The information contained in this manual

was based on machines in production at the time of publication. Generac Mobile Products reserves the right to

change any portion of this information without notice.

Read all of the manuals included with the unit. Each manual details specific information regarding items such as

setup, use and service requirements. An engine operator’s manual provides detailed operation and maintenance

procedures for the engine. Additional copies of the engine operator’s manual are available from the engine

manufacturer.

DO NOT MODIFY or use this equipment for any application other than for which it was designed.

Generac Mobile Products recommends that a trained and licensed professional perform all electrical wiring and

testing functions. Any wiring should be in compliance with the National Electrical Code (NEC), state and local

regulations and Occupational Safety and Health Association (OSHA) guidelines.

GENERAC MOBILE PRODUCTS LLC

215 Power Drive • Berlin, WI 54923

U.S.A.

Phone: 920-361-4442

FAX: 920-361-4416

Toll Free: 1-800-926-9768

www.generacmobile.com

For technical or parts QUESTIONS, please contact the Generac Mobile Products Customer Support

or Technical Support team at 1-800-926-9768. Please have your serial number available.

To ORDER SERVICE PARTS, please contact the dealer from which you purchased the unit, or call

Generac Mobile Products to locate a dealer in your area.

Engine Make:__________________________________________

Engine Serial Number:___________________________________

Engine Model Number: __________________________________

Generator Make: _______________________________________

Generator Model Number:________________________________

Generator Serial Number: ________________________________

Unit Model Number:_____________________________________

Unit Serial Number: _____________________________________

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Table of Contents

Introduction............................................................................................................................ iii

Section 1 - Safety

Safety Notes.......................................................................................................................................1

Operating Safety.................................................................................................................................1

Engine Safety.....................................................................................................................................2

Service Safety ....................................................................................................................................2

Reporting Trailer Safety Defects ........................................................................................................3

Section 2 - General Information

Specifications .....................................................................................................................................5

Unit Dimensions ....................................................................................................................6

Engine Oil Recommendations...............................................................................................6

Coolant Recommendations ...................................................................................................6

Unit Serial Number Locations.............................................................................................................7

Control Panel....................................................................................................................................10

Engine/Generator Protective Devices ..............................................................................................12

Fuel/Water Filtering System.............................................................................................................13

Section 3 - Operation

Prestart Checklist .............................................................................................................................15

Manually Starting the Unit ................................................................................................................15

Auto (Remote) Starting of the Unit ...................................................................................................15

Parallel Setup and Operation ...........................................................................................................16

Derating for Altitude..........................................................................................................................17

Wet Stacking ....................................................................................................................................17

Generator Output Connections.........................................................................................................17

Main Circuit Breaker.........................................................................................................................19

Transfer Switch.................................................................................................................................19

Shutting Down the Unit.....................................................................................................................20

Emergency Stop Switch ...................................................................................................................21

Transporting the Unit........................................................................................................................21

Section 4 - Maintenance

Shutting Down and Restarting the Generator...................................................................................23

Raising and Lowering the Stairs.......................................................................................................23

Lowering the Stairs..............................................................................................................23

Raising the Stairs ................................................................................................................25

Daily Walk Around Inspection...........................................................................................................25

Checking the Coolant Level.................................................................................................26

Checking the Oil Level.........................................................................................................26

Changing the Oil..................................................................................................................27

Maintenance Schedule.....................................................................................................................28

Fuel/Water Filtering System Maintenance........................................................................................30

Draining the Fuel/Water Separators....................................................................................30

Replacing the Filter Element ...............................................................................................30

Section 5 - Troubleshooting

General Troubleshooting..................................................................................................................31

Service Log ............................................................................................................................ 33

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37789 ORG MCG1000MT2 Operating Manual 1

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.

The following formatting options will apply when calling the readers attention to the DANGERS, WARN-

INGS, CAUTIONS, NOTICES and NOTES.

DANGER

INDICATES A HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN

DEATH OR SERIOUS INJURY.

WARNING

Indicates a hazardous situation which, if not avoided, may result in death or serious

injury.

CAUTION

Indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.

Indicates a hazardous situation which, if not avoided, may result in property or equipment

damage.

Note: Notes contain additional information important to a procedure and will be found within the regular text body

of this manual.

OPERATING SAFETY

Before using the unit, be sure you read and 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

and controls. Inexperienced operators should receive instruction from someone familiar with the equipment

before being allowed to operate or set up the unit. The following points should be practiced at all times:

• The area immediately surrounding the unit should be dry, clean, and free of debris.

• Position and operate the unit on a firm, level surface.

• NEVER start a unit in need of repair.

• If the unit is equipped with a frame grounding stud, follow any local, state, and National Electrical

Code (NEC) guidelines when connecting.

• NEVER operate the unit on a combustible surface.

• NEVER operate a unit while tired, distracted, or under the influence of drugs or alcohol.

• Keep all body parts, clothing and other loose items away from moving parts.

• DO NOT fill fuel tank near an open flame, while smoking, or while engine is running. DO NOT fill tank

in an enclosed area with poor ventilation.

• DO NOT operate with the fuel tank cap loose or missing.

• Shut the engine down if any of the following conditions exist during operation:

Safety

2 MCG1000MT2 Operating Manual 37789 ORG

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. Failure to follow the

safety guidelines described below could result in severe injury or death. Read and follow all safety warnings

described in the engine operator's manual. A copy of this manual was supplied with the unit when it was

shipped from the factory.

• DO NOT run engine indoors or in an area with poor ventilation unless exhaust hoses are used. Engine

exhaust contains carbon monoxide, a deadly, odorless and colorless gas which, if inhaled, can cause

nausea, fainting or death. Make sure engine exhaust cannot seep into closed rooms or ventilation

equipment.

• DO NOT touch or lean against hot exhaust pipes or engine components.

• DO NOT clean air filter with gasoline or other types of low flash point solvents.

• DO NOT operate the unit without a functional exhaust system.

• Prolonged exposure to sound levels in excess of 85 dB(A) can cause permanent hearing loss. Wear

hearing protection when working around a running engine.

• Batteries contain sulfuric acid which can cause severe injury or death. Sulfuric acid can cause eye

damage, burn flesh 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.

• NEVER open the radiator cap or oil drain plug while the engine is running or before the engine has

cooled down. Pressurized coolant and hot engine oil can cause severe burns. Allow the unit to cool

completely before attempting any service work.

• Keep area around exhaust pipes and air ducts free of debris to reduce the chance of an accidental fire.

SERVICE SAFETY

All service work must be performed by qualified personnel who are familiar with the equipment. Only a

qualified electrician should troubleshoot or repair electrical problems occurring in this equipment. Fol-

low the safety guidelines described below to prevent hazardous situations which could result in severe

injury or death.

• NEVER wash the unit with high pressure hoses, power washers, or steam cleaners. Water may collect

in the unit, causing damage to electrical parts.

• ALWAYS use extreme caution when servicing this unit in damp conditions. Do not service the unit if

your skin or clothing is wet. Do not allow water to collect around the base of the unit.

• Inspect condition of electrical wiring. DO NOT use the unit if wires are damaged or insulation is cut

or worn through.

• Replace all missing and hard to read decals. Decals provide important operating instructions and

warn of dangers and hazards.

• Before servicing the unit, make sure the Control Power switch and battery disconnect are in the OFF

position. NEVER perform even routine service (oil/filter changes, cleaning, etc.) unless all electrical

components are shut down.

Safety

37789 ORG MCG1000MT2 Operating Manual 3

• NEVER start the unit under load. The circuit breaker must be off when starting the unit.

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 Products

LLC.

If NHTSA receives similar complaints, it may open an investigation; and 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 individual

problem between you, your dealer, or Generac Mobile Products LLC.

To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-888-327-4236 (TTY:1-800-424-9153),

go to http://www.safercar.gov; or write to:

Administrator

NHTSA

1200 New Jersey Avenue S.E.

Washington, DC 20590

You can also obtain other information about motor vehicle safety from http://www.safercar.gov.

Safety

4 MCG1000MT2 Operating Manual 37789 ORG

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37789 ORG MCG1000MT2 Operating Manual 5

Section 2 - General Information

SPECIFICATIONS

GENERAC MODEL MCG1000MT2

Engine

Make/Brand...........................................................................................................................Mitsubishi

Model....................................................................................................................................S12H-Y2PTAW-1

EPA Tier................................................................................................................................2

Aspiration..............................................................................................................................Turbocharged, Intercooled

Horsepower - Prime hp (kW) ...............................................................................................1528 (1140)

Operating Speed rpm ..........................................................................................................1800

Displacement in

(L) ............................................................................................................37.1 (2265)

Cylinders - qty.......................................................................................................................12

Fuel Consumption - 100% prime gph (Lph) ........................................................................70.9 (268.4)

Battery Type..........................................................................................................................Group 8D

Battery Voltage (Quantity per Unit) .......................................................................................24V (4)

Battery Rating.......................................................................................................................1100 CCA

Generator

Make/Brand...........................................................................................................................Marathon

Model....................................................................................................................................741RSL8045

Type, Insulation.....................................................................................................................Brushless, H

Generator Set (Engine/Generator)

3Ø - Standby kW (kVA) .......................................................................................................1000 (1250)

Amps - 3Ø Standby (480V) A ...............................................................................................1503

3Ø - Prime kW (kVA) ...........................................................................................................900 (1125)

Amps - 3Ø Prime (480V) A ..................................................................................................1353

Frequency Hz .......................................................................................................................60

Power Factor.........................................................................................................................0.8 (3Ø)

Weights

Operating Weight lbs (kg) ...................................................................................................42110

Capacities

Fuel Tank Volume gal (L) .....................................................................................................1360 (5148)

Coolant (incl. engine) qt (L) .................................................................................................106 (401)

Oil (incl. filter) qt (L) ............................................................................................................. 52.8 (200)

AC Distribution

Circuit Breaker Size ..............................................................................................................1600A

Voltages Available 3Ø...........................................................................................................277/480

Trailer

Number of Axles....................................................................................................................2

Capacity - Axle Rating lbs (kg) ea. ......................................................................................22500 (10205)

Tire Size in ...........................................................................................................................11R22.5

Tire Load Range ...................................................................................................................G 14PR

Maximum Tire Pressure psi .................................................................................................105

Specifications are subject to change without notice.

General Information

6 MCG1000MT2 Operating Manual 37789 ORG

Unit Dimensions

Figure 1 - Unit Dimensions

Specifications are subject to change without notice.

Engine Oil Recommendations

Generac Mobile Products recommends the use of 15W-40 engine oil, with a minimum American Petroleum Institute

(API) Service Class of CF class 1. Refer to the engine operation manual, included with this unit, for more detailed

oil grade and viscosity information.

Coolant Recommendations

WARNING

Risk of poisoning. Do not use mouth to siphon coolant. Doing so could result in death

or serious injury.

WARNING

Disconnect the negative battery terminal before servicing to prevent accidental

engine rotation. Failure to do so could result in death or serious injury.

Use of improper coolants can damage the engine cooling system. Use demineralized water or distilled water for best

results. Hard water causes scale deposits, which reduces cooling efficiency and raises internal temperatures, possibly

leading to engine damage. Use an anticorrosive to prevent rot in summer and anti-freeze to prevent freezing in winter.

Dilute the anti-freeze based on a theoretical temperature that is 9-18°F (5-10°C) below the lowest temperature

expected in the area. A ratio of 40-60% is most common.

Note: Use only Peak Fleet-Charge

50/50 ethylene glycol type coolant (available from any authorized Generac

dealer). Be sure to use maroon colored coolant for diesel engines.

ABC

MCG1000MT2 96 in. (2.43 m) 157.5 in. (4.0 m) 488 in. (12.4 m)

Freezing Point °F (°C)

(-16)

-13

(-25)

-31

(-35)

-58

(-50)

-54

(-48)

Coolant (% Volume) 30 40 50 60 70

Water (% Volume) 70 60 50 40 30

01858

General Information

37789 ORG MCG1000MT2 Operating Manual 7

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.

Record the information from these tags so it is available if the tags are lost or damaged. When ordering parts or

requesting assistance, you may be asked to provide this information.

Figure 2 - Serial Number Locations

TIRE AND LOADING INFORMATION

RENSEIGNEMENTS SUR LES

PNEUS ET LE CHARGEMENT

SEE OWNER’S

MANUAL FOR

ADDITIONAL

INFORMATION

VOIR LE

MANUEL DE

L’USAGER

POUR

PLUS DE

RENSEIGNEMENTS

MANUFACTURED BY/FABRIQUE PAR: Magnum Power Products LLC DATE: 00/0000

GVWR/PNBV: 000KG (0000LBS) COLD INF. PRESS./

PRESS. DE

V.I.N./N.I.V.:

00000000000000000

TYPE:

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 SECURITE DES VEHICULES AUTOMOBILES DU CANADA EN VIGUEUR A LA DATE SA

FABRICATION.

The weight of cargo should never exceed 0000KG (0000LBS)

Le poids du chargement ne doit jamais depasser 0000KG (0000LBS)

Serial Number

Model

KVA

Manufacturing Code

1 ph. 1.0PF 3 ph. .8PF 3 ph. 1.0PF

Country of Origin

Weight (lbs/kg) RPM/Frequency

Rating

Ins. Class

FOR ELECTRICAL EQUIPMENT

ONLY. POUR MATERIAL

ELECTRIQUE SEULEMENT.

209649

Form: SFC626B

Manufactured by Magnum Power Products, LLC.,

a subsidiary of Generac Power Systems, Inc.

(920) 361-4442 (800) 926-9768

Unit ID Tag (Located

behind control panel door)

VIN Tag

01859

General Information

8 MCG1000MT2 Operating Manual 37789 ORG

COMPONENT LOCATIONS

Figure 3 - Left Side

1. Sound attenuation baffles (3) 8. Plenum drain (in container floor)

2. Digital speed control 9. Block heater (aftercooler)

3. Diffuser 10. Oil level indicator

4. Muffler 11. Starter

5. Radiator 12. Spill containment pan

6. Discharge plenum 13. Storage box (manuals)

7. Fuel tank - 1360 gallon (5148 liter)

534

01861

General Information

37789 ORG MCG1000MT2 Operating Manual 9

Figure 4 - Right Side

1. Air filter (2) 10. Fuel/water separator

2. Crankcase vent 11. Engine oil drain

3. Battery charger 12. Coolant drain

4. Batteries - 8D (4) 13. Engine oil dipstick

5. Battery disconnect switch 14. Block heater (jacket water)

6. Control panel 15. Oil filter

7. Receptacle panel (under container) 16. Bypass oil filter

8. Starter 17. Engine oil fill port

9. Fuel filter (4)

1112

01862

General Information

10 MCG1000MT2 Operating Manual 37789 ORG

CONTROL PANEL

Figure 5 - Control Panel

1. DC circuit breaker - control 5. Alarm horn

2. Control panel light 6. Panel lights

3. DC circuit breaker - interior lights 7. Digital controller

4. DC circuit breaker - exterior lights 8. Emergency stop switch

DC CIRCUIT

BREAKER

CONTROL

HORN

DC CIRCUIT

BREAKER

INTERIOR LIGHTS

DC CIRCUIT

BREAKER

EXTERIOR LIGHTS

EMERGENCY STOP

PANEL LIGHTS

OFF

01863

General Information

37789 ORG MCG1000MT2 Operating Manual 11

CONNECTION PANEL

Connections for the block heaters, battery charger, AC lights, etc. are located in a swing-down panel located under

the container, on the right side of the unit (beneath the circuit breaker panel). Two receptacles are provided for

paralleling multiple units. These receptacles are not routed through the main circuit breaker.

Figure 6 - Input Receptacles

The GFCI receptacle is located directly inside the door on the left side of the container. Refer to Figure 7. The GFCI

receptacle receives power from the connection in the swing-down panel.

Numerous lights are provided throughout the container and inside the main circuit break box. Sixty minute timers

are provided for delayed shut off of the lights.

Figure 7 - GFCI Receptacle and Interior Light Timer

1. Block heater - 240VAC (50A) twist-lock 4. GFCI receptacle - 120VAC NEMA 5-15P

2. Block heater - 240VAC NEMA 6-15P 5. AC lights - 120VAC NEMA 5-15P

3. Battery charger - 120VAC NEMA 5-15P 6. CAN connection receptacle (2)

01869

01860

GFCI

Receptacle

Interior

Light

Timer

General Information

12 MCG1000MT2 Operating Manual 37789 ORG

DIGITAL CONTROLLER

The DSE8610 is a synchronizing auto start control module suitable for use in a multi-generator loadshare system.

It is designed to synchronize up to 32 generators, including electronic and non-electronic engines. Refer to “Parallel

Setup and Operation” on page 16 for more information on paralleling.

Figure 8 - Controller Features

The DSE8610 monitors the generator and indicates operational status and fault conditions, automatically starting or

stopping the engine on load demand or fault condition. System alarms are displayed on the LCD screen (multiple

language options available), illuminated LED, and audible alarm.

The event log will record 250 events to facilitate easy maintenance. An extensive number of fixed and flexible

monitoring, metering and protection features are included, as well as comprehensive communication and system

expansion options. Refer to the DSE8610 Control and Instrumentation Operators Manual included with this unit for

more information.

ENGINE/GENERATOR PROTECTIVE DEVICES

The unit may be required to operate for long periods of time without an operator on hand to monitor conditions such

as coolant temperature, oil pressure, voltage, frequency, etc. For this reason, the unit has numerous sensors to

provide the control panel with the information it needs to protect both the engine and generator. The control panel

is designed to shut down the engine if potentially damaging conditions occur. These conditions can include low oil

pressure, high coolant temperature, low coolant level, engine overspeed, over or under voltage, over or under

frequency, etc. These settings are configured at the factory and can be adjusted by an Authorized Service Technician

if required.

1. Menu navigation buttons 7. Mute alarm/lamp test

2. Main status and instrumentation display 8. Select Auto mode

3. Configurable LEDs (4) 9. Close generator LED - On when genera-

tor required to be on load

4. Gen-Set (close main circuit breaker) 10. Select Manual mode

5. Generator available LED - On when gen-

erator is within limits and able to take load

11. Select Stop mode

6. Start engine (manual mode) 12. Load (open main circuit breaker)

01864

General Information

37789 ORG MCG1000MT2 Operating Manual 13

FUEL/WATER FILTERING SYSTEM

The fuel/water separator assemblies protect engine components from dirt, rust, algae, varnishes, and water, which

is prevalent in engine fuels. They remove contaminates from the fuel using a three stage process.

Stage One: Separation

As fuel enters the filter assembly, it moves through the internal check valve, then through the turbine centrifuge where

it flows in a spiraling direction, spinning off large solids and water droplets which fall to the bottom of the collection bowl.

Figure 9 - Fuel/Water Separators

Stage Two: Coalescing

Small water droplets bead up on the surface of the conical baffle and cartridge element. When heavy enough, they

too fall to the bottom of the bowl.

Stage Three: Filtration

The cartridge elements repel water and remove contaminants from the fuel down to 30 micron (nominal).

Note: All valves must be open during operation. Check prior to starting the unit.

01865

General Information

14 MCG1000MT2 Operating Manual 37789 ORG

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Generac MCG1000 Operating instructions

Brand: Generac

Model: MCG1000

Category: Power generators

Type: Operating instructions

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Generac MCG1000 Operating instructions

Generac MCG1000 Operating instructions

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