Generac Power Systems MAGNUM User manual

SAVE THIS MANUAL FOR FUTURE REFERENCE
MODEL NUMBER: _________________________
SERIAL NUMBER: _________________________
DATE PURCHASED:________________________
Self-Prime Diesel Trash Pump
Owner’s Manual
MTP4DZD • MTP4DZV • MTP6DZD • MTP6DZV
002073
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ii Owner’s Manual for Dry-Prime Diesel Trash Pumps
(000004)
WARNING
California Proposition 65. Engine exhaust and some
of its constituents are known to the state of California
to cause cancer, birth defects, and other reproductive
harm.
(000005)
WARNING
California Proposition 65. This product contains or
emits chemicals known to the state of California to
cause cancer, birth defects, and other reproductive
harm.
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Owner’s Manual for Dry-Prime Diesel Trash Pumps iii
Table of Contents
Section 1 Introduction and Safety
Introduction ..................................................................1
Safety Rules .................................................................1
General Hazards ...........................................................1
Explosion and Fire Hazards ........................................2
Trailer Hazards .............................................................2
Battery Hazards ............................................................2
Pump Hazards ..............................................................3
Reporting Trailer Safety Defects ................................3
Section 2 General Information
Unit Dimensions ...........................................................5
Unit Serial Number Locations .....................................6
Component Locations .................................................9
Trailer Tongue Preparation for Use ..........................13
Hood Operation ..........................................................14
To open the rear hood: ..............................................14
To close the rear hood: .............................................14
Welding on Equipment with
Electronic Controls ....................................................15
Section 3 Operation
Control Panel Operation ............................................17
LED Indicators ............................................................17
Auto Standby LED (Green) ........................................17
Preheat LED (Amber) ................................................17
Engine Stop LED (Red) .............................................17
Warning LED (Amber) ...............................................17
Throttle Control ..........................................................17
Ramp Throttle (Speed Control Switch) ....................18
Automatic START and STOP ....................................18
Start and Stop Events ................................................19
Start and Stop Modes: ...............................................19
Start and Stop Functions: ..........................................19
Maintain Functions ....................................................19
Dead Band ................................................................20
Digital Controller ........................................................20
Button Lock ................................................................20
Analog Gauge Pages .................................................21
Digital Gauge Pages ..................................................21
Single Analog Gauge .................................................21
Analog Transducer/Switch Gauge ...........................22
Digital Transducer Gauge .........................................22
Active Alarms .............................................................22
Alarm List ...................................................................22
Configuration Menu ...................................................22
Display Menu ..............................................................23
Units Menu ..................................................................23
Language Menu ..........................................................23
Button Beep ................................................................23
Gauges Menu .............................................................23
Max RPM .....................................................................24
Max Speed ..................................................................24
Quad Adjust ................................................................24
Voltmeter ....................................................................24
Service Timers ...........................................................24
System Menu ..............................................................24
Demo .........................................................................24
Restore Defaults ........................................................24
Com Viewer ...............................................................25
J1939 Viewer .............................................................25
Engine Configuration .................................................25
J1939 Settings ...........................................................25
Engine Source ...........................................................26
Display CAN Add .......................................................26
Alarm Filter ................................................................26
SPN Version ..............................................................26
Speed Source ............................................................26
PIN Settings ..............................................................26
PIN Entry ...................................................................26
PIN Change ...............................................................26
About .........................................................................27
Autostart Menu ...........................................................27
Mode .........................................................................27
Function .....................................................................27
Throttling Menu .........................................................27
Idle RPM ....................................................................28
Intermediate RPM .....................................................28
Run RPM ...................................................................28
Ramp Up/Down .........................................................28
Servo .........................................................................28
Transducer ................................................................28
Starter ........................................................................29
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iv Owner’s Manual for Dry-Prime Diesel Trash Pumps
Settings Menu ............................................................ 29
Governor ................................................................... 29
CP750 CAN Add ....................................................... 29
Calibrate RPM ........................................................... 29
Aux Output ................................................................ 30
Alarm Settings ........................................................... 30
Telemetry Menu ......................................................... 30
Telem J1939 Address ............................................... 30
Modbus Address ....................................................... 30
Status ........................................................................ 30
DB Viewer ................................................................... 31
Preferred Screen Store ............................................. 31
Pop-Up Messages and Alerts ................................... 31
Service Required ...................................................... 31
Data Communications Failure ................................... 31
Data Not Available .................................................... 31
Adjusting Lighting and Contrast .............................. 31
Data Parameters Monitored ...................................... 32
Pump Set Up .............................................................. 34
Pump Pre-use Checkpoints ...................................... 36
Prestart Checklist ...................................................... 36
Starting the Unit ......................................................... 37
Flow Rates .................................................................. 38
Diaphragm Pump System ......................................... 39
Operation .................................................................... 39
Mechanical Seal ......................................................... 39
Liquid Temperature and Overheating ...................... 39
Pump Vacuum Check ................................................ 39
Bearing Temperature Check ..................................... 39
Stopping The Unit ...................................................... 39
Emergency Stop Switch ............................................ 40
Automatic Shutdown ................................................. 40
Remote/Auto Starting Option ................................... 40
Towing the Unit .......................................................... 40
Lifting the Unit ........................................................... 41
Section 4 Maintenance
Daily Walk Around Inspection .................................. 43
General Maintenance ................................................ 44
Checking the Engine Oil ........................................... 44
Checking the Oil Level Sight Gauge
(Diaphragm Pump Only) .............................................. 45
Changing the Engine Oil ........................................... 45
Changing the Oil Filter .............................................. 45
Adding Coolant .......................................................... 45
Jack Maintenance ...................................................... 45
Side-Wind Models ..................................................... 45
Top-Wind Models ...................................................... 46
Wear Rings ................................................................. 46
Servicing The Pump .................................................. 46
Pump Disassembly ................................................... 46
Pump Assembly ........................................................ 48
Impeller Lockscrew Installation ............................... 49
Lubrication ................................................................ 49
Impeller Lockscrew Removal .................................... 49
Frame Disassembly and Assembly ......................... 49
Disassembly ............................................................. 49
Assembly .................................................................. 50
Lubrication Instructions ........................................... 50
Mechanical Seal Maintenance .................................. 50
Mechanical Seal Oil .................................................. 50
Removing the Mechanical Seal ................................ 51
Removing the O-ring Seat ........................................ 51
Installing the O-ring Seat .......................................... 51
Installing the Mechanical Seal .................................. 51
Priming Chamber ...................................................... 52
Float Removal ........................................................... 52
Installation ................................................................. 52
Prime Valve Removal and Installation ...................... 52
Float Valve Linkage Removal and Installation .......... 52
Linkage Replacement ............................................... 52
Strainer/Baffle ........................................................... 52
Separator .................................................................. 52
Discharge Check Valve ............................................. 53
Maintenance ............................................................. 53
Disassembly ............................................................. 53
Assembly .................................................................. 53
Diaphragm Pump System ......................................... 54
Disassembly ............................................................. 54
Assembly .................................................................. 56
Suction Valve Removal and
Installation ................................................................. 56
Actuator Neck Seal Removal and Installation ........ 56
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Owner’s Manual for Dry-Prime Diesel Trash Pumps v
Table of Contents
Crankshaft Removal and
Installation ..................................................................56
Removal ....................................................................56
Installation .................................................................57
Crankshaft Lip Seal Removal and Installation ........57
Roller Bearing Removal and
Installation ..................................................................57
Connecting Rod/Drive Rod Assembly .....................57
Pedestal Bearing and Seals Removal
and Installation ...........................................................58
Trailer Wheel Bearings ..............................................58
Storage ........................................................................58
Extended Storage Preparation ..................................58
Winter Storage ...........................................................58
Commission Unit for Use ..........................................58
Section 5 Troubleshooting
Pump Troubleshooting Guide ..................................59
Engine Fault Shutdown Troubleshooting ................60
Control System Troubleshooting .............................61
Diagnostic Trouble Codes (DTS) ..............................61
SPN Codes ................................................................61
FMI Codes .................................................................62
Section 6 Installation Diagrams and Service
Log
DC Wiring Diagram ....................................................63
Trailer Lights Wiring Diagram ...................................64
Service Log .................................................................65
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Owner’s Manual for Dry-Prime Diesel Trash Pumps 1
Introduction and Safety
Section 1 Introduction and Safety
Introduction
Thank you for purchasing a Generac Mobile Product.
This unit has been designed to provide high-
performance, efficient operation, and years of quality
use when maintained properly.
The unit is mounted on a trailer that has a chain
attach point. The fully enclosed design protects the
operating components, allowing all-weather storage
and operations.
The unit is mounted on a trailer that has a chain
attach point. The fully enclosed design protects the
operating components, allowing all-weather storage
and operations.
If any section of the manual is not understood, con-
tact your nearest Authorized Service Dealer.
The owner is responsible for proper maintenance
and safe use of the equipment.
SAVE THESE INSTRUCTIONS for future reference.
This manual contains important instructions for the
pump that should be followed during installation,
operation and maintenance of the pump and
batteries. ALWAYS supply this manual to any
individual that will use this machine.
THE INFORMATION CONTAINED HEREIN WAS
BASED ON MACHINES IN PRODUCTION AT THE
TIME OF PUBLICATION. GENERAC RESERVES THE
RIGHT TO MODIFY THIS MANUAL AT ANY TIME.
Safety Rules
The manufacturer cannot anticipate every possible
circumstance that might involve a hazard. The warn-
ings in this manual, and on tags and decals affixed to
the unit are, therefore, not all inclusive. If using a
procedure, work method or operating technique that
the manufacturer does not specifically recommend,
verify that it is safe for others. Also verify the proce-
dure, work method or operating technique utilized
does not render the equipment unsafe.
Throughout this publication, and on tags and decals
affixed to the unit, DANGER, WARNING, CAUTION,
and NOTE blocks are used to alert personnel to spe-
cial instructions about a particular operation that
may be hazardous if performed incorrectly or care-
lessly. Observe them carefully. Their definitions are
as follows:
NOTE: Notes contain additional information important to
a procedure and will be found within the regular text of
this manual.
These safety alerts cannot eliminate the hazards that
they indicate. Common sense and strict compliance
with the special instructions while performing the
action or service are essential to preventing acci-
dents.
General Hazards
(000100a)
WARNING
Consult Manual. Read and understand manual
completely before using product. Failure to
completely understand manual and product
could result in death or serious injury.
(000001)
DANGER
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
(000002)
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
(000003)
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Asphyxiation. Running engines produce
carbon monoxide, a colorless, odorless,
poisonous gas. Carbon monoxide, if not
avoided, will result in death or serious injury.
(000103)
DANGER
WARNING
Do not operate this unit while transporting.
Doing so could result in death or serious
injury.
(000231)
(000107)
WARNING
Hearing Loss. Hearing protection is
recommended when using this machine.
Failure to wear hearing protection could
result in permanant hearing loss.
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2 Owner’s Manual for Dry-Prime Diesel Trash Pumps
Introduction and Safety
Explosion and Fire Hazards
Trailer Hazards
Battery Hazards
(000111)
WARNING
Moving Parts. Keep clothing, hair, and
appendages away from moving parts. Failure
to do so could result in death or serious injury.
(000108)
WARNING
Hot Surfaces. When operating machine, do not
touch hot surfaces. Keep machine away from
combustibles during use. Hot surfaces
could result in severe burns or fire.
CAUTION
(000229)
Equipment or property damage. Do not block
air intake or restrict proper air flow. Doing so
could result in unsafe operation or damage
to unit.
CAUTION
(000246)
Equipment Damage. The emergency stop switch
is not to be used to power down the unit under
normal operating circumstances. Doing so will
result in equipment damage.
(000105)
DANGER
Explosion and Fire. Fuel and vapors are
extremely flammable and explosive. Add fuel
in a well ventilated area. Keep fire and spark
away. Failure to do so will result in death
or serious injury.
(000147)
WARNING
Risk of Fire. Unit must be positioned in a
manner that prevents combustible material
accumulation underneath. Failure to do so
could result in death or serious injury.
WARNING
Trailer must be securely coupled to the hitch
and chains correctly attached. Uncoupled or
unchained towing could result in death or serious
injury. (000233)
WARNING
Verify unit is properly secured with wheel
chocks and on level ground. Failure to do so
could result in death or serious injury.
(000234)
WARNING
Property or Equipment Damage. Tighten wheel lug
nuts after first 50 miles to factory specifications.
Failure to do so could result in death, serious injury,
property or equipment damage. (000235)
(000137a)
WARNING
(000162)
WARNING
Explosion. Do not dispose of batteries in a fire.
Batteries are explosive. Electrolyte solution can cause
burns and blindness. If electrolyte contacts skin or eyes,
flush with water and seek immediate medical attention.
(000163a)
WARNING
Risk of burn. Do not open or mutilate batteries.
Batteries contain electrolyte solution which can
cause burns and blindness. If electrolyte contacts
skin or eyes, flush with water and seek immediate
medical attention.
(000130)
WARNING
Accidental Start-up. Disconnect the negative battery
cable, then the positive battery cable when working
on unit. Failure to do so could result in death
or serious injury.
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)
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Owner’s Manual for Dry-Prime Diesel Trash Pumps 3
Introduction and Safety
Pump Hazards 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 imme-
diately inform the National Highway Traffic Safety Admin-
istration (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 cam-
paign. 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.
WARNING
Personal Injury. Do not pump volatile, corrosive, or
flammable materials. Doing so could result in death
or serious injury and pump damage.
(000271)
WARNING
Personal Injury. Verify all hoses are securely
fastened. Failure to do so could result in death
or serious injury.
(000272)
WARNING
Personal Injury. Do not operate pump with flow
completely restricted. Doing so could cause pump
casing to explode and could result in death or
serious injury. (000273)
WARNING
Personal Injury. Allow pump to cool completely before
removal of any parts. Failure to do so could cause
parts to be ejected with great force and could cause
death or serious injury. (000274)
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Owner’s Manual for Dry-Prime Diesel Trash Pumps 5
General Information
Section 2 General Information
Unit Dimensions
Figure 2-1. Unit Dimensions
Specifications are subject to change without notice.
002132
A
B
C
D
AB C D
MTP4DVD
75.00 in (1.905 m) 73.88 in (1.877 m) 150.12 in (3.813 m) 98.00 in (2.489 m)
MTP4DVZ
MTP6DVD
MTP6DVZ
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6 Owner’s Manual for Dry-Prime Diesel Trash Pumps
General Information
Unit Serial Number Locations
Figure 2-2. Serial Number Locations
Safety Decal Locations
NOTE: Locations may vary slightly from unit to unit.
002291
ID Description ID Description
A General safety: keep hands clear of belt, hot surfaces,
and fan, and do not remove guard
N Beware of moving blades
B Float switch port location P Suction port location
C Do not step Q Fuel tank drain location
D Tie down location R Discharge port location
E Towing instructions S Lubricant Grease every 1500 hours for optional
equipment
F Operator’s manual storage location T Lubricant Grease every 1500 hours
G Disconnect battery before servicing U Engine oil drain location
H Fuel requirement V Engine coolant drain location
J Stop the engine. Do not smoke while refueling. Do not
breathe in fuel vapors. See the operators manual for
further instructions. Fill the tank with diesel.
W Disconnect battery before servicing
K Autostart, understand operator’s manual before opera-
tion, hearing protection required while operating unit
X Hot surface
L Pump operation instructions Y Lifting point
M Do not pump dangerous liquids. Z Keep hands free of belt
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Owner’s Manual for Dry-Prime Diesel Trash Pumps 7
General Information
A
B
C
C
D
E
F
G
H
J
K
LM
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8 Owner’s Manual for Dry-Prime Diesel Trash Pumps
General Information
P
C
N
Q
D
R
S
T
U
K
G
A
V
XYZ
W
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Owner’s Manual for Dry-Prime Diesel Trash Pumps 9
General Information
Component Locations
Figure 2-3. Left Side (6 Inch DZV Pump Shown)
A. Air cleaner I. Battery
B. Central lift point J. Fuel filter (main)
C. Rear leveling jacks (2) K. Coolant drain
D. Priming chamber L. Engine oil dipstick
E. Pump inlet (suction) port M. Engine oil filter
F. Pump outlet (discharge) port N. Front leveling jack
G. Fuel pre-filter O. Tie down ring
H. Engine oil drain
002073
L
O
N
M
G
J
I
C
F
D
A
B
K
H
C
E
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10 Owner’s Manual for Dry-Prime Diesel Trash Pumps
General Information
Figure 2-4. Right Side (6 Inch DZV Pump Shown)
A. Mechanical seal oil reservoir G. Control panel
B. Compressor H. Fuel fill port
C. DOC I. Tie down rings
D. Radiator sight glass J. Rear leveling jacks
E. Emergency stop switch K. Fuel tank drain
F. Manual holder
002130
A
B
C
D
E
F
G
H
I
J
J
K
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Owner’s Manual for Dry-Prime Diesel Trash Pumps 11
General Information
Figure 2-5. Venturi-Prime Pump Components - Left Side (4 Inch Shown)
A. Belt and guard K. Suction cover
B. Compressor L. Volute
C. Compressor output fitting M. Backplate
D. Compressor hose N. Mechanical seal
E. Mechanical seal oil reservoir O. Frame bracket
F. Relief valve P. Grease fittings
G. Venturi fitting Q. Bearing frame
H. Priming chamber R. Compressor bracket
I. Suction spool S. Drive end shaft and key
J. Air discharge hose
002333
A
BC
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
P
S
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12 Owner’s Manual for Dry-Prime Diesel Trash Pumps
General Information
Figure 2-6. Diaphragm Vacuum Pump Components - Left Side (4 Inch Shown)
A. Diaphragm vacuum pump G. Run dry gland
B. Air discharge hose H. Grease fittings
C. Mechanical seal oil reservoir I. Frame
D. Priming chamber J. Shaft and Drive end shaft key
E. Suction spool K. Belt and guard
F. Volute
002334
A
B
C
D
E
F
G
H
I
J
K
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Owner’s Manual for Dry-Prime Diesel Trash Pumps 13
General Information
Trailer Tongue Preparation for Use
If the unit is shipped with the trailer tongue in the upright
position, follow the steps below to lower the tongue.
1. See Figure 2-7. Move the front jack from the
tongue to the location shown and lower the jack.
2. Lower the rear jacks to prevent the unit from
tipping backwards during procedure.
Figure 2-7. Install Tongue Jack
3. See Figure 2-8. Loosen but do not remove the
nylon lock nuts on bolts Aand B.
4. Remove the lower bolt and nylon lock nut securing
the tongue braces to the tongue (C).
Figure 2-8. Remove Lower Bolt
5. See Figure 2-9. Move the right tongue brace (D)
upward to allow access and then remove the rear
bolts and nylon lock nuts (E) as shown.
Figure 2-9. Remove Rear Bolts
6. See Figure 2-10. Remove the upper bolt, nut, and
washers (F) to allow the tongue to pivot.
Figure 2-10. Remove Upper Bolt, Nut, and Washer
7. See Figure 2-11. Lower the trailer tongue and
install bolts (E) removed in step 4 with new nylon
lock nuts. Do not tighten until bolt (G) is installed
and tightened.
Figure 2-11. Lower Tongue
8. See Figure 2-12. Align the lower holes on the
tongue braces with the slot in the tongue. Install
the bolt with a new nylon lock nut (G). Tighten to
80-109 ft-lbs (108-148 Nm).
9. Tighten bolt (E) to 80-109 ft-lbs (108-148 Nm).
10. Install the upper bolt, nut, and washers (F) in the
hole near the top of the tongue mounting bracket.
The bolt should be snug against the bracket.
11. Tighten the nylon lock nuts on bolts Aand Bto 80-
109 ft-lbs (108-148 Nm).
Figure 2-12. Install Fasteners
002314
002315
A
C
A
B
002342
D
E
E
002343
F
002344
002317
E
E
G
G
F
F
A
A
B
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14 Owner’s Manual for Dry-Prime Diesel Trash Pumps
General Information
Hood Operation
Figure 2-13. Hood Latches
NOTE: Pump enclosures are optional.
To open the rear hood:
1. Verify there is proper clearance to accommodate
swing of hood to the full-open position.
2. Release hood latches.
3. Stand at the rear of the unit and firmly grasp the
handle at the rear of the hood and slowly tilt the
hood rearward until fully open.
NOTE: Pump hoods are heavy. Use caution when
opening or closing.
To close the rear hood:
1. Verify all contact surfaces for hood are clean of
debris.
2. Stand at the rear of the unit and firmly grasp the
handle at the rear of the hood and slowly tilt the
hood forward until fully closed.
3. Verify hood has fully seated and secure the hood
latches.
002312
WARNING
Pinch Point. Hood could slam shut. Keep
hands and fingers clear. Failure to do so
could result in death or serious injury.
(000267)
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Owner’s Manual for Dry-Prime Diesel Trash Pumps 15
General Information
Welding on Equipment with
Electronic Controls
Proper welding procedures are required to avoid damage
to electronic controls, sensors and associated compo-
nents. The component should be removed for welding if
possible.
The following procedure must be followed if the component
must be welded while installed on equipment with elec-
tronic controls. This procedure will minimize the risk of
component damage.
NOTE: Do not ground the welder to electrical
components such as the control ground or sensors.
Improper grounding can cause damage to electrical
components. Clamp the ground cable from the welder to
the component being welded. Place the clamp as close
as possible to the weld to reduce the possibility of
damage.
1. Stop the engine. Turn the Key switch to the OFF
position.
2. Disconnect the negative (-) battery cable from the
battery.
3. Open any installed Battery Disconnect switch.
4. Unplug the control system if possible.
5. Connect the welding ground cable as close as
possible to the area to be welded.
6. Protect the wiring harness from welding debris and
splatter.
7. Use standard welding methods to weld the
materials.
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