Axiom megagen x48 User manual
ELECTRIC POWER
GENERATOR
MODEL x48
OPERATOR'S MANUAL
2
LIMITED WARRANTY
GENERAL TERMS AND CONDITIONS
The product warranty is subject to the manufacturer’s general terms and conditions of sale.
Acknowledgment of the warranty depends on the strict and proven observance of the operating instructions
in this operator’s manual and application of the correct mechanical and electro-technical practices.
The warranty will not be valid in the event of:
• Tampering with the generator (modifications without prior authorisation);
• Breakdown due to lack of or inadequate protection and/or incorrect connection;
• Breakdown caused by exceeding the rating plate limits;
• Normal wear and tear of the generator;
• Non-compliance by the personnel in charge of installation of the operational regulations given;
• Accidental causes, natural disasters of every kind, e.g., fires, floods, water or lightning;
• It is the customers responsibility to register the unit engine with the respective OEM to obtain warranty;
The warranty provides that:
-
tionable judgement on the reason for the defect.
damage to people or objects.
Warranty period from shipment date:
SPARE PARTS
WARRANTY VOID IF NOT REGISTERED
megagen
3
ELECTRIC POWER GENERATOR
DEALER INSPECTION REPORT SAFETY
______
______
______
______
______
______
______
______
______
WARRANTY REGISTRATION FORM & INSPECTION REPORT
Date _______________________________ ____________________________
____________________________
Date ________________________________ ________________________________
WARRANTY REGISTRATION
delivery.
__________________________ ___________________________
Address__________________________________ Address________________________________
____________________________________________
___________________
___________________________
_____________________
_________________________
_______________________
Delivery Date ______________________________
megagen
4
Model Number ___________________________
Serial Number Machine A ___________________________
Engine B ___________________________
Alternator C ___________________________
SERIAL NUMBER LOCATIONS
Always give your dealer the serial number of your megagen x48 generator when ordering
parts or requesting service or other information.
The serial number plates are located where indicated. Please mark the number in the space provided for
easy reference.
MACHINE
ENGINE
ALTERNATOR
AC
5
TABLE OF CONTENTS
SECTION DESCRIPTION PAGE
1Introduction .......................................................... 7
2 Safety .................................................................... 8
2.1 General Safety....................................................... 9
9
2.2 Equipment Safety Guidelines ...............................10
2.3 Safety Training ......................................................11
2.4 Safety Signs..........................................................11
2.5 Storage Safety ......................................................11
2.6 Preparation Safety ................................................12
2.7 Installation Safety .................................................12
2.8 Maintenance Safety ..............................................13
2.9 Lock-Out Tag-Out Safety.......................................13
2.10 Battery Safety .......................................................13
2.11 Operating Safety...................................................14
2.12 Tire Safety.............................................................14
2.13 Transport Safety....................................................14
2.14 Electrical Safety ....................................................14
2.15 Diesel Engine Safety
2.16 Refueling Safety....................................................15
2.17 Sign-Off Form
3 Safety Sign Locations ....................................... 17
4 Operation............................................................ 18
4.1 To the New Operator or Owner............................ 18
4.2 Machine Components.......................................... 19
4.3 Machine Break-In................................................. 0.
4.4 Pre-Operation Checklist....................................... 0.
4.5 Controls ............................................................... 21
4.6 Machine Preparation............................................ 24
4.7 Operation ............................................................. 28
2
2,,66Storage ................................................................ 33
22,,77 Transport.............................................................. 34
5 Service and Maintenance.................................. 3366
5.1 Service................................................................. 36
5.2 Maintenance ........................................................ 42
6 Trouble Shooting ............................................... 4
466
7 .................................................... 4477
7.1 Mechanical........................................................... 47
7.2 Bolt Torque........................................................... 48
7.3 Electrical Schematic ............................................ 49
8 Index ................................................................... 5555
............................................15
.......................................................16
6
7
1 INTRODUCTION
Congratulations onyour choice of a megagen x48 generator and welcome to megagen's quality line of gener-
ating equipment. This equipment is designed and manufactured to meet the needs of a discriminating buyerin the
industry for generation of electric power.
Safe, efficient andtrouble free operation of your new megagen x48 generatorrequires that you, and anyone
else who will be operating or maintaining the machine, read, understand and practice ALL of the Safety, Operation,
Maintenance and Trouble Shooting recommendations contained within this Operator's Manual.
megagen
This manual applies to all x48 generator manufactured by megagen. Certain options may be available to
specifically tailor the generator to your operation and may not be included in this manual. Please contact the
manufacturer regarding additional information about these options. Use the Table of Contents and Index as a
guide to find specific information.
The information in this manual is accurate based on products produced at the time of publication. The manufac-
turer reserves the right to make technical updates, corrections and product revisions at any time without notice.
The warnings in this manual and on decals on the unit are not all inclusive. If using a procedure or operating
techniques that the manufacturer does not specifically recommend, verify that it is safe for others. Also, make
sure the procedure does not render the equipment unsafe.
Keep this manual handy for frequent reference and so that it will be passed on to new operators or owners. Call your
megagen dealer ifyou need assistance, information oradditional copies of this manual.
8
2SAFETY
SAFETY ALERT SYMBOL
If you have any questions not answered in this manual or require additional copies or the manual is damaged,
Accidents Disable and Kill
Accidents Cost You Money
Accidents Can Be Avoided
Why is SAFETY important to you?
This Safety Alert symbol means
ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
3 Big Reasons
DANGER - Indicates an imminently hazardous situ-
ation that, if not avoided, will result in
death or serious injury. This signal word
is to be limited to the most extreme situa-
tions, typically for machine components
that, for functional purposes, cannot be
guarded.
WARNING - Indicates a potentially hazardous situ-
ation that, if not avoided, could result
in death or serious injury, and includes
hazards that are exposed when guards
are removed.It may also be used to alert
against unsafe practices.
CAUTION - Indicates a potentially hazardous situ-
ation that, if not avoided, may result in
minor or moderate injury. It may also be
used to alert against unsafe practices.
SIGNAL WORDS:
Note the use of the signal words DANGER,
WARNING and CAUTION with the safety
messages. The appropriate signal word for each
message has been selected using the following
guide-lines:
The Safety Alert symbol identifies
important safety messages on your
megagen generator and in the
manual. When you see this symbol,
be alert to the possibility of personal
injury or death. Follow the instructions
in the safety message.
9
2.1GENERAL SAFETY
Operator's Manual and all safe-
ty signs before supplying pow-
er to, operating, maintaining or
adjusting the generator.
operate this machine.
of an accident. Store in a highly vis-
ible place.
case of an accident. Store in a highly
visible place.
and shields before
operating.
protective gear. This
list includes but
is not limited to:
- Protective shoes
with slip resis-
tant soles
- Protective glasses
or goggles
- Heavy gloves
- Hearing protection
, y l ppusr ewopt uok co ldnanwodt uhs, no i t i sop
and wait for all moving parts to stop before servic-
ing, adjusting, maintaining, repairing or cleaning.
any pages and keep it away from moisture and
heat sources. Please note that the drawings con-
tained in the manual are merely to help you iden-
tify the parts described and, therefore, they might
notcorrespond precisely to your product.
your area.
annually.
SAFETY
YOU are responsible for the SAFE operation and
maintenance of your megagen generator. YOU
must ensure that you and anyone else who is going to
operate, maintain or work around the machine be
familiar with the operating and maintenance proce-
dures and related SAFETY information contained in
this manual. This manual will take you step-by-step
through your working day and alerts you to all good
safety practices while operating the generator.
YOU are the key to safety. Good safety
practices not only protect you but, also the people
around you. Make these practices a working part of
your safety program. Be certain that EVERYONE op-
erating this machine is familiar with the procedures
-
risk injury or death by ignoring good safety practices.
and all safety signs before supplying power to,
operating, maintaining oradjusting the generator.
-
tions to operators or employees before allowing
them to operate the machine, and at least annu-
ally thereafter.
-
ment is a SAFE operator. It is the operator’s re-
sponsibility to read and understand ALL Safety
and Operating instructions in the manual and to
follow these. Most accidentscanbe avoided.
-
operate this machine. An untrained operator ex-
poses himself and bystanders to possible serious
injury or death.
-
tion and/or safety and could affect the life of the
equipment.
-
tation for the engine and the alternator: we rec-
ommend keeping it all in a safe place and have
case of transfer of equipment ownership, attach
all the documentation, as it is an integral part of
theproduct.
departmentis available to assist you in any way.
required; failure to comply will void your warranty
automatically.
10
2.2 EQUIPMENT SAFETY GUIDELINES
the main concerns in designing and developing a
machine. However, every year many accidents oc-
cur which could have been avoided by a few sec-
onds of thought and a more careful approach to
handling equipment. You, the operator, can avoid
many accidents by observing the following pre-
cautions in this section. To avoid personal injury or
death, study the following precautions and insist
those working with you, or for you, follow them.
-
graphs or illustrations in this manual may show an
assembly with a safety shield removed. However,
equipment should never be operated in this con-
dition. Keep all shields in place. If shield removal
becomes necessary for repairs, replace the shield
prior to use.
not readable or is missing. Location of such safety
signs isindicated in this manual.
can hinder alertness or coordination while oper-
ating this equipment. Consult your doctor about
operating this machine while taking prescription
medications.
Under no circumstances should young chil-
dren be allowed to work with this equipment.
Do not allow persons to operate or assemble
this unit until they have read this manual and
have developed a thorough understanding of
the safety precautions and of how it works.
annually.
persons unfamiliar with its operation. The opera-
tor should be a responsible, properly trained and
physically able person familiar with the machinery
and trained in this equipment's operations. If the
elderly are assisting with work, their physical limi-
tations need to be recognized and accommodated.
its ability to do a job, or to do so safely, is in ques-
tion - DON'T TRY IT.
or death and may impair the function and life of the
equipment.
manufacturer reserves the right to make chang-
es and improvements to accessories and details
without altering the essential characteristics of the
model described and illustrated here and without
committing to promptly updating this manual.
implement, including Safety Signs and Safety
Equipment, hazard control and accident preven-
tion are dependent upon the awareness, concern,
prudence, and proper training of personnel in-
volved in the operation, transport, maintenance,
Messages and operation instruction in each of the
appropriate sections of the auxiliary equipment
and machine Manuals. Pay close attention to the
Safety Signs affixed to the auxiliary equipment
andthe machine.
electrical power that can injure or kill if not oper-
all instructions.
11
2.3SAFETY TRAINING
Safety is a primary concern in the design and man-
ufacture of our products. Unfortunately, our efforts
to provide safe equipment can be wiped out by a
single careless act of an operator or bystander.
equipment, hazard control and accident preven-
tion are dependent upon the awareness, con-
cern, prudence and proper training of personnel
involved in the operation, transport, maintenance
andstorage of this equipment.
safety feature is an informed,
to be that kind of an operator.
It is the operator's responsibility
to read and understand ALL Safety and Operating
instructions in the manual and to follow these.
Accidents can be avoided.
Working with unfamiliar equipment can lead
to careless injuries. Read this manual, and the
manual for your auxiliary equipment, before
assembly or operating, to acquaint yourself
with the machines. If this machine is used by
any person other than yourself. It is the ma-
chine owner's responsibility to make certain
that the operator, prior to operating:
i. Reads and understands the operator's
manuals.
ii.Is instructed in safe and properuse.
Know your controls and how to stop generators
and any other auxiliary equipment quickly in an
-
ed with your other equipment.
frequently with existing workers. Be certain only
a properly trained and physically able person will
operate the machinery. A person who has not read
and understood all operating and safety instruc-
untrained operator exposes himself and bystand-
ers to possible serious injury or death. If the elder-
ly are assisting with work, their physical limitations
need to be recognized and accommodated.
2.4SAFETY SIGNS
Keepsafety signs clean and legible at all times.
-
come illegible.
also display the current sign.
Safety signs displayed in Section 3 each have a
part number in the lower right-hand corner. Use
this part number when ordering replacement
parts.
Safety signs are available from your authorized
facto r y.
How to Install Safety Signs:
paper.
-
ly press the small portion with the exposed sticky
backing in place.
-
fully smooth the remaining portion of the sign in
place.
smoothed out using the piece of sign backing
paper.
2.5 STORAGE SAFETY
are safely and positively connected before storing.
stored generator.
or junction box and padlocking the door shut to
prevent electrocution or unauthorized start up of
thegenerator.
and behind the tires before unhooking from tow
vehicles.
12
2.7INSTALLATION SAFETY
where it can provide maximum power with mini-
mal interference with the access and operation of
other equipment. Select a different position if there
is interference.
surface to avoid tipping, sliding or falls during op-
eration. Avoid placing the unit on a surface with a
-
gases away from the worksite.
compliance with local laws and regulations.
-
ponents must always be in good condition when
operating.
-
tion. Open and latch the doors when the engine is
stopped andmachine is being serviced.
clean to allow engine to cool when running. Clean
when trash plugs slots.
-
from high temperatures.
-
tion occurs. Identify and resolve the malfunction
before turning machine on and resuming work.
2.6 PREPARATION SAFETY
-
ment until you have read and completely un-
derstand this manual, the auxiliary equipment
Operator's Manual, and each of the Safety
Messages found on the safety signs on the gen-
erator and auxiliary equipment.
-
tion equipment in-
cluding hard hat,
safety glasses,
safety shoes, and
gloves are recom-
mended during
assembly, instal-
lation, operation,
adjustment, main-
taining, repair-
-
around equipment.
PROLONGED EXPOSURE
TO LOUD NOISE MAY CAUSE
PERMANENT HEARING LOSS!
Motors or equipment attached
can often be noisy enough to
cause permanent, partial hear-
ing loss. We recommend that you wear hearing
protection on a full-time basis if the noise in the
Operator's position exceeds 80db. Noise over
85db on a long-term basis can cause severe hear-
ing loss. Noise over 90db adjacent to the Operator
over a long-term basis may cause permanent,
total hearing loss. NOTE:Hearing loss from loud
a lifetimewithouthope ofnatural recovery.
-
stacles that might be hooked or snagged, causing
injury, damage or tripping.
andin good operating condition.
are properly installed and in good condition.
any loose bolts, worn parts, cracks, leaks, frayed
belts and make necessary repairs. Always follow
maintenance instructions.
13
2.8 MAINTENANCE SAFETY
in the Operator's Manual regarding operating, ser-
vicing, adjusting, maintaining and repairing.
Turn machine OFF, shut down and lock out
power supply and wait for all moving parts to
stop before servicing, adjusting, maintaining
or repairing.
-Keep service area clean
anddr y.
-Be sure electrical out-
lets and tools are properly
grounded.
-Use adequate light for the
jobat hand.
properly secured when operating the generator.
-
cal system unless the power cord
is unplugged or the power supply is
locked out. Lock-out tag-out power
source before performing any main-
tenance work.
readily accessible while
performing maintenance
on this equipment.
tall moving parts to stop before performing any
service or maintenance or work on them.
while engine is running. Allow engine to cool be-
fore performing any service work on it.
doors when service and repair work has been
completed.
-
ning or still hot to prevent leaks and scalding
burns.
2.9LOCK-OUT TAG-OUT SAFETY
your operation.
allowing them to work around thegenerator.
to record tag out details.
motor is OFF and the power locked out with the
master switch.
2.10 BATTERY SAFETY
away from batteries, as
gas given off by electrolyte
is explosive. Always wear
gloves.
spilled electrolyte immediately.
-
lyte loss.
-
nect battery ground cable before servicing any
part ofthe electrical system.
14
2.11 OPERATING SAFETY
all safety signs before operating, maintaining, ad-
justing or repairing the generator.
their OFF position shut down and lock out power
source, unplug power cord and wait for all moving
parts to stop before servicing, adjusting, repairing
or unplugging.
good repair.
children.
-
ly with megagen approved parts.
moving parts.
electrical power accessibility and minimal interfer-
ence with other equipment.
-
jure or kill. Follow appropriate safety procedures.
your operation and train all operators and service
personnel before allowing them work with and
around the generator.
machine.
Keepothers off.
2.12 TIRE SAFETY
-
ing a tire on a wheel or rim can produce an explo-
sion which may result in serious injury ordeath.
properequipment and experience to do the job.
-
form required tire maintenance.
2.13 TRANSPORT SAFETY
state/provincial and federal regulations regarding
transporting equipment onpublic roadways.
-
-
lock pin.
lights required by law are in proper place and are
clearly visible to oncoming and overtaking traffic.
the towing vehicle. Use a safety cable to assure a
safe hitchhook-up when transporting.
-
ing transport.
personnel.
prevent changing the center of gravity or overload-
ing the frame.
with trailer. Slow down for corners and rough sur-
face conditions.
2.14 ELECTRICAL SAFETY
compliance with local laws and regulations.
-
ponents must always be in good condition when
operating.
when shutting down unit.
15
2.15 DIESELENGINE SAFETY
BEFORE STARTING ENGINE, READ AND UNDER-
STAND THE OPERATING AND MAINTENANCE IN-
STRUCTIONS THAT CAME WITH YOUR ENGINE.
WARNING: DO NOT
gases contain carbon monoxide, an odorless and
deadly poison.
-
ingparts.
-
ter heater which use a pilot light or devices which
cancreate a spark.
-
tilated. Outdoor refuelling is preferred.
engine to cool for 5 minutes before refuelling. Store
fuel in approved safety containers.
running.
machine away from the spill and avoid creating
any ignitionuntil the fuel has evaporated.
speed before stopping.
may result in injury.
thegoverned engine speed.
by theoriginalequipment manufacturer.
-
tion. Useproper tools to service engine.
periodically and replace, if necessary. If engine is
-
grass, leaves, dirt or other combustible materials
in the muffler area.
brush covered, or grass covered unimproved land
unless a spark arrester is installed on the muffler.
The arrester must be maintained in effective work-
ing order by the operator. In the State of California
may have similar laws. Federal laws apply on fed-
eral lands.
because contact may cause burns.
cover removed.
WARNING: DO
switch before servicing engine to prevent acciden-
tal starting.
functioning effectively. A worn or leaking muffler
should be repaired or replaced asnecessary.
system.
2.16 REFUELLING SAFETY
-
ling. Clean up spilled fuel before restarting engine.
sparks.
-
mulated trash, grease anddebris.
16
2.17 EMPLOYEE SIGN-OFF FORM
-
ally review this information before the season start-up.
A sign-off sheet is provided for your record keeping to show that all personnel who will be working with the
equipment have read and understand the information in the Operator’s Manual and have been instructed in the
operation of the equipment. Copy this page and use it as your sign-off form
SIGN-OFF FORM
DATE EMPLOYEE'S SIGNATURE EMPLOYER'S SIGNATURE
megagen follows the general Safety Standards specified by the American Society of Agricultural and
Biological Engineers (ASABE) and the Occupational Safety and Health Administration (OSHA). Anyone who
will be operating and/or maintaining a megagen built machine must read and clearly understand ALL
Safety, Operating and Maintenance information presented in this manual.
17
B
A
3 SAFETY SIGN LOCATIONS
The types of safety signs and locations on the equipment are shown in the illustrations that follow. Good safety
REMEMBER - If Safety Signs have been damaged, removed, become illegible or parts replaced without safety
signs, new signs must be applied. New safety signs are available from your authorized dealer. The types of
safety signs and locations on the equipment are shown in the illustrations that follow. Good safety requires
that you familiarize yourself with the various Safety Signs, the type of warning and the area, or particular
function related to that area, that requires your SAFETY AWARENESS.
• Think SAFETY! Work SAFELY!
requires that you familiarize yourself with the various Safety Signs, the type of warning and the area, or particu-
3.1 Model x48
C
18
4OPERATION
and all safety signs before operating, maintain-
ing, adjusting or repairing the generator.
their OFF position shut down and lock out power
source, unplug power cord and wait for all mov-
ing parts to stop before servicing, adjusting, re-
pairingor unplugging.
good repair.
children.
-
ately with megagen approved parts.
moving parts.
OPERATING SAFETY
electrical power accessibility and minimal inter-
ference with other equipment.
-
er to injure or kill. Follow appropriate safety
procedures.
for your operation and train all operators and
service personnel before allowing them work
with andaround thegenerator.
themachine.
Keepothers off.
4.1 TO THE NEW OPERATOR OR OWNER
The megagen generator is designed to provide
electrical power to areas where the power grid isn't
available using a diesel engine as a power source.
It is the responsibility of the owner or operator to
read this manual and to train all other operators
before they start working with the machine. In ad-
-
ment, hazard control and accident prevention are
dependent upon the awareness, concern, and
prudence of personnel involved in the operation,
transport, maintenance and storage of equipment
or in the use of facilities.
Follow all safety instructions exactly. Safety is
everyone's business. By following recommended
procedures, a safe working environment is pro-
vided for the operator, bystanders and the area
around the worksite. Untrained operators are not
Many features incorporated into this machine are the
result of suggestions made by customers like you.
machine safely and how to set it to provide maximum
efficiency. By following the operating instructions in
conjunction with a good maintenance program, your
megagen generator will provide many years of
trouble-free service.
19
4.2 MACHINE COMPONENTS
The megagen generator is a diesel engine powering
an alternator to generate electricity. This electricity is
used to provide power to equipment or systems that
require electric power in remote areas or where
connecting to the grid is inconvenient, impossible or
not appropriate.
Batteries inside the frame provide power to start the
engine. All controls and electrical connections are on
the left side of the frame.
A lift loop is mounted on top of the frame as a conve-
nience to the operator when required.
Slots and a screen on each end of the frame allow air
components.
FIG. 1 MACHINE & TANK COMPONENTS (TYPICAL)
A Air Filter
B
C
D
E
F
G
H
J
K
ComAp
Power Cable Connection
Power Plug-Ins
System Switches
Engine
Muffler
Exhaust
L
M
N
O
P
Q
R
S
Lift Loop
Alternator
Battery
Battery Disconnect Switch
Fuel Cap
Fuel Tank
Emergency stop
Voltage Selector
Auxiliary Fuel Intake
Auxiliary Fuel Selector
Engine, radiator, muffler, fuel tank, are all mounted
inside the frame. Exhaust is direct out the top of the
frame and away from the working area. Fitt ings are
provided to attach an auxiliary fuel tank to the unit to
provide longer running time between refuelling. The
fuel tank is mounted under the engine and convenient
to refuel. the alternator is mounted on the flywheel
housing to eliminate any drivetrain components.
Five connections with breakers are available to connect
to 120V, 240V and 480V with various amp loadings and
single and 3 phase outputs.
AA
HH
FFKK
OO
JJ
GG
EE
CCDD
BB
PP
NN
RR
QQ
MM
LL
SS
20
4.3 MACHINE BREAK-IN
Although there are no operational restrictions on the
megagen generator when used for the first time,
it is recommended that the following mechanical
items be checked:
-
erator's engine and alternator. Follow break-in
procedures.
B. After 2, 5 and 10 hours ofoperation:
2.
Check that all electrical connections are
tight and cords are routed out of the way or
protected.
Clean air flow louvers.
3. Check levels in engine. Top up as required.
C. Break in service required at 75 hours:
Drain engine oil and change engine oil filter.
Then continue with regular service intervals of
every 500 hours
D. After 500 hours of operation:
with recommended oil.
2. Replace fuel screen filter and water trap fuel
filter.
3. Then go to regularly scheduled service
schedule.
4.4PRE-OPERATION CHECKLIST
protective gear is in
good repair and avail-
able for use by each
operator. Make cer-
tain that each opera-
tor uses the protec-
tive gear. Protective
gear includes but, is
not limited to:
-Gloves
- Safety glassesor face shield
- Full length protective clothing
- Steel toed boots with slip resistant soles.
- Hearing protection.
good repair and securely in place.
OFF position before starting engine.
and cords are routed out of the way or protected.
prevent tripping or slipping.
Safe and efficient operation of your new generator
requires that each operator reads and follows all safety
precautions and operating procedures contained in this
section. Performing the following pre-operation check-
list is important for personal safety as well as for contin-
ued mechanical soundness and longevity of your new
megagen generator. The checklist should be
performed before operating the generator and prior to
each operation thereafter.
Table of contents
