MEGAGEN Z150 User manual

MODEL Z150 OPERATOR'S
MANUAL
megagen

LIMITED megagen Z SERIES WARRANTY
This limited warranty is issued by megagen for the supply of the following products: megagen Z
Series Generators.
2DESCRIPTION AND WARRANTY PERIOD
Machine: Without prejudice to the legal warranty, megagen. extends the warranty on manufacturing
defects relating to the equipment supplied up to a period of 4 (four) years/ 4000 hour (whichever comes
first) from the date of sale (invoice). Therefore, the total legal and limited warranty period will be 4 (four)
years/ 4000 hour (whichever comes first) from the invoice date. The determination whether the product is
defective will be made by Axiom Equipment Inc. in its sole discretion, considering the general
performance given by the product.
3WARRANTY TERMS AND CONDITIONS
The guarantee is valid provided that:
•The products are stored, installed, used and maintained in compliance with the technical
specifications indicated in the product marking (with specific reference to the voltage and operating
temperature), to the instructions supplied with the product, to what is indicated in the respective
catalogs and to the standards in force;
•Installation and maintenance are carried out by qualified technical personnel, all service records must
be available for warranty purposes;
•The reported defect affects the functionality of the product;
•The product has not been modified, altered or treated with chemicals or in any other way in any way;
•The product covered by the guarantee is made available to megagen for further technical
analysis for the time necessary to carry it out;
•The defect is reported in writing, by certified or registered email with return receipt to megagen
within 30 (thirty) days from the receipt of the products (in the case of apparent defects) or from the
discovery of the defect (in the case of hidden defects) by sending a photographic feedback of the
label on the product;
In the event that the defect is recognized by megagen, megagen will choose at its discretion
whether to repair or replace the defective product with the same product or an equivalent one, taking into
consideration the technical evolution of the products and that of their components. Any technical
intervention or replacement (partial or complete) of the product carried out pursuant to the warranty will
not in any case give the right to extensions or renewals of the same beyond 4 (four) years/ 4000 hour
(whichever comes first) from the invoice date. The repair and replacement of the product recognized as
defective by Axiom Equipment Inc. does not include costs or expenses for its removal or reinstallation.
Axiom Equipment Inc. is not responsible for, and therefore will not reimburse, any consequential loss or
indirect, compensatory or other damage suffered due to a defective products, such as, by way of example
and not limited to, shipping costs, assembly costs, on-site installation, any downtime costs, loss of profit
or overall cost of buyers.
4. EXCLUSIONS AND LIMITATIONS
This limited warranty does not cover:
•Labour costs and expenses, equipment and warehouse costs and expenses, or any other extra costs
relating to and / or resulting from any intervention necessary to repair the defect (such as, by way of
example, costs / expenses for assembly, disassembly, and transport of defective appliances, to be
repaired or new products which will be the sole responsibility of the customer);
•Electrical products subject to wear which are comparable to consumables;
•Products made on specific customer request;
•Damage to products due to negligence, transportation or unforeseen and unforeseeable events that
do not fall within normal conditions of use (such as, for example, electric shock and lightning);
•Appliances not used for the purpose for which they were made;
This warranty does not guarantee the integrity of the painting when the product is used in a saline
environment or in the presence of corrosive agents.

In no event megagen will be liable for accidental, compensatory, consequential, indirect, special or
other damages. The liability of megagen for a defect in the product will in any case be limited to the
amount actually paid for that defective product.
The performance and duration of the LEDs are not guaranteed if the fixtures are installed in environments
with the presence of chemical substances that are not compatible with the LEDs themselves. Our
technical office is available to check the compatibility of the LEDs we use in relations to the substances
present in the environment where the luminaires are installed.
5. APPLICABLE LAW AND JURISDICTION
This limited warranty, as well as its execution, interpretation and all questions concerning the validity and
effectiveness of the same, will be governed by Canadian Law.
It is the responsibility of the owner to register the engine and alternator with each OEM for warranty
purposes.
SPARE PARTS
Spare parts manual is available for this unit.
WARRANTY VOID IF NOT REGISTERED

megagen
ELECTRIC POWER GENERATOR
DEALER INSPECTION REPORT SAFETY
______ Guards/ShieldsInstalled&Secured
______ AllDecalsInstalled&Legible
______ SafetyChainonHitch(Ifontrailer)
______ ReviewOperatingandSafetyInstructions
______ TirePressureChecked(Ifontrailer)
______ WheelBoltsTorqued(Ifontrailer)
______ InspectElectricalSystem
______ CheckOilLevelinHydraulicReservoir
______ LubricateMachine
______ CheckEngineFluidLevels
WARRANTY REGISTRATION FORM & INSPECTION REPORT
IhavethoroughlyinstructedthebuyerontheabovedescribedequipmentwhichreviewincludedtheOperator’s
Manualcontent,equipmentcare,adjustments,safeoperationandapplicablewarrantypolicy.
Date _______________________________ Dealer’sRep.Signature ____________________________
Signature ____________________________
TheaboveequipmentandOperator’sManualhavebeenreceivedbymeandIhavebeenthoroughlyinstructed
astocare,adjustments,safeoperationandapplicablewarrantypolicy.
Date ________________________________ Owner'sSignature ________________________________
WARRANTY REGISTRATION
Thisformmustbefilledoutbythedealerandsignedbyboththedealerandthecustomeratthetimeof
delivery.
Customer’sName __________________________Dealer'sName ___________________________
Address __________________________________ Address ________________________________
City,State/Prov.,Code _______________________City,State/Prov.,Code _____________________
PhoneNumber(_____) ___________________
GeneratorModel ___________________________
SerialNumberAlternator _____________________
UnitSerialNumber _________________________
SerialNumberEngine _______________________
Delivery Date ______________________________
WHITE YELLOW PINK
MEGAGEN DEALER CUSTOMER

SERIAL NUMBER LOCATIONS
Always give your dealer the serial number of your megagenZ150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.
Model Z100
Serial Number Machine ___________________________
Engine ___________________________
Alternator ___________________________
z150
ENGINE ALTERNATOR

TABLE OF CONTENTS
SECTION DESCRIPTION PAGE
1 Introduction .......................................................... 1
2 Safety .................................................................... 3
2.1 GeneralSafety ....................................................... 4
2.2 EquipmentSafetyGuidelines ................................ 5
2.3 SafetyTraining ....................................................... 6
2.4 SafetySigns ........................................................... 6
2.5 StorageSafety ....................................................... 6
2.6 PreparationSafety ................................................. 7
2.7 InstallationSafety .................................................. 7
2.8 MaintenanceSafety ............................................... 8
2.9 Lock-OutTag-OutSafety........................................ 8
2.10 BatterySafety ........................................................ 8
2.11 OperatingSafety .................................................... 9
2.12 TireSafety .............................................................. 9
2.13 TransportSafety ..................................................... 9
2.14 ElectricalSafety ..................................................... 9
2.15 DieselEngineSafety ............................................10
2.16 RefuelingSafety....................................................10
2.17 RefillingDEFSafety ..............................................11
2.18 Sign-OffForm ...................................................... 12
3 Safety Sign Locations ....................................... 13
4 Operation ............................................................ 15
4.1 TotheNewOperatororOwner ............................ 15
4.2 MachineComponents .......................................... 16
4.3 MachineBreak-In ................................................. 18
4.4 Pre-OperationChecklist ....................................... 18
4.5 Controls ............................................................... 19
4.6 MachinePreparation ............................................ 22
4.7 Operation ............................................................. 26
4.9 Storage ................................................................ 31
4.12 Transport .............................................................. 32
5 Service and Maintenance .................................. 35
5.1 Service ................................................................. 35
5.2 Maintenance ........................................................ 41
6 Trouble Shooting ............................................... 45
7 Specifications .................................................... 47
7.1 Mechanical ........................................................... 47
7.2 BoltTorque ........................................................... 49
7.3 ElectricalSchematic ............................................ 50
8 Index ................................................................... 51

1
1 INTRODUCTION
Congratulations on your choice of a megagen Z150 generator and welcome to megagen's quality line
of generating equipment. This equipment is designed and manufactured to meet the needs of a customer who
needs a portable, cost-effective source of electrical power.
Safe, efficient and trouble free operation of your new megagen Z150 generator requires that you, and
any-one 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.
This manual applies to all Z150 generators 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 if you need assistance, information or additional copies of this manual.

2

3
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 instruc-
tions in the safety message.
2 SAFETY
SAFETY ALERT SYMBOL
If you have any questions not answered in this manual or require additional copies or the manual is damaged,
please contact your dealer or megagen, Phone: [phone], Email: service@axiomequipmentgroup.
com.
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:

4
2.1 GENERAL SAFETY
• Readandunderstandthe
Operator's Manual and all safe-
ty signs before supplying pow-
er to, operating, maintaining or
adjusting the generator.
• Onlytrained,competentpersonsshalloperatethe
generator. An untrained operator is not qualified to
operate this machine.
• Provideafirst-aidkitforuseincase
of an accident. Store in a highly vis-
ible place.
• Provideafireextinguisherforusein
case of an accident. Store in a highly
visible place.
• Installandproperlysecureallguards
and shields before
operating.
• Wearappropriate
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
• TurnmachineOFF,placeallcontrolsintheirOFF
position, shut down and lockout power supply,
and wait for all moving parts to stop before servic-
ing, adjusting, maintaining, repairing or cleaning.
• Donotdamagethismanual,donotremoveortear
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
not correspond precisely to your product.
• Knowtheemergencymedicalcenternumberfor
your area.
• Reviewsafetyrelateditemswithalloperators
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.
Remember,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
recommendedandfollowssafetyprecautions.Re-
member,mostaccidentscanbeprevented.Donot
risk injury or death by ignoring good safety practices.
• ReadandunderstandtheOperator'sManual
and all safety signs before supplying power to,
operating, maintaining or adjusting the generator.
• Generatorownersmustgiveoperatinginstruc-
tions to operators or employees before allowing
them to operate the machine, and at least annu-
ally thereafter.
• Themostimportantsafetydeviceonthisequip-
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 accidents can be avoided.
• Apersonwhohasnotreadandunderstoodallop-
erating and safety instructions is not qualified to
operate this machine. An untrained operator ex-
poses himself and bystanders to possible serious
injury or death.
• Donotmodifytheequipmentinanyway.
Unauthorized modification may impair the func-
tion and/or safety and could affect the life of the
equipment.
• Themanualcomeswiththeoriginaldocumen-
tation for the engine and the alternator: we rec-
ommend keeping it all in a safe place and have
qualified personnel to carry out operations. In
case of transfer of equipment ownership, attach
all the documentation, as it is an integral part of
the product.
• Ourcustomerserviceandtechnicalassistance
department is available to assist you in any way.
• Onlyusegenuinepartsincasereplacementis
required; failure to comply will void your warranty
automatically.

5
2.2 EQUIPMENT SAFETY GUIDELINES
• Safetyoftheoperatorandbystandersisoneof
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.
• Inordertoprovideabetterview,certainphoto-
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.
• Replaceanysafetysignorinstructionsignthatis
not readable or is missing. Location of such safety
signs is indicated in this manual.
• Neverusealcoholicbeveragesordrugswhich
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.
Reviewthesafetyinstructionswithallusers
annually.
• Thisequipmentisdangeroustochildrenand
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.
• Neverexceedthelimitsofapieceofmachinery.If
its ability to do a job, or to do so safely, is in ques-
tion - DON'T TRY IT.
•Donotmodifytheequipmentinanyway.
Unauthorized modification result in serious injury
or death and may impair the function and life of the
equipment.
• Thecontentsofthismanualarenotbinding.The
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.
• Inadditiontothedesignandconfigurationofthis
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,
andstorageofthemachine.ReferalsotoSafety
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
and the machine.
• Thismachineisdesignedtogeneratehighvoltage
electrical power that can injure or kill if not oper-
atedproperly.Readoperator'smanualandfollow
all instructions.

6
2.3 SAFETY 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.
• Inadditiontothedesignandconfigurationof
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
and storage of this equipment.
• Ithasbeensaid,"Thebest
safety feature is an informed,
carefuloperator."Weaskyou
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 proper use.
• Know your controls and how to stop generators
and any other auxiliary equipment quickly in an
emergency.Readthismanualandtheoneprovid-
ed with your other equipment.
• Trainallnewpersonnelandreviewinstructions
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-
tions is not qualified to operate the machine. An
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.
2.4 SAFETY SIGNS
• Keep safety signs clean and legible at all times.
• Replacesafetysignsthataremissingorhavebe-
come illegible.
• Replacedpartsthatdisplayedasafetysignshould
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
DistributororDealerPartsDepartmentorthe
factory.
How to Install Safety Signs:
• Besurethattheinstallationareaiscleananddry.
• Besuretemperatureisabove50°F(10°C).
• Determineexactpositionbeforeyouremovethe
backingpaper.(SeeSection3).
• Removethesmallestportionofthesplitbacking
paper.
• Alignthesignoverthespecifiedareaandcareful-
ly press the small portion with the exposed sticky
backing in place.
• Slowlypeelbacktheremainingpaperandcare-
fully smooth the remaining portion of the sign in
place.
• Smallairpocketscanbepiercedwithapinand
smoothed out using the piece of sign backing
paper.
2.5 STORAGE SAFETY
• Storethegeneratoronafirmlevelsurface.
• Ifrequired,makesuretheunitisfirmlyblockedup.
• Makecertainthatallmechanicallocksandjacks
are safely and positively connected before storing.
• Storeawayfromareasofhumanactivity.
• Donotallowchildrentoplayonoraroundthe
stored generator.
• Lockoutpowerbyturningoffmastercontrolpanel
or junction box and padlocking the door shut to
prevent electrocution or unauthorized start up of
the generator.
• Ifmountedonatrailer,placechocksinfrontof
and behind the tires before unhooking from tow
vehicles.

7
2.7 INSTALLATION SAFETY
• Reviewlayoutoftheworksite.Positiongenerator
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.
• Positiongeneratorbaseortraileronasolid,level
surface to avoid tipping, sliding or falls during op-
eration. Avoid placing the unit on a surface with a
slopeofover10°.
• Positionmachinesotheengineexhaustisdirect-
edawayfrompersonnelontheworksite.Directthe
gases away from the worksite.
• Usegroundterminalinsideframetogroundunitin
compliance with local laws and regulations.
• Donotoperatemachinewithwethandsorclothing.
• Allelectricalwires,plugs,socketsandothercom-
ponents must always be in good condition when
operating.
• Closeandlatchthedoorsduringnormalopera-
tion. Open and latch the doors when the engine is
stopped and machine is being serviced.
• Keepenginecoolingslotsondoorsandframe
clean to allow engine to cool when running. Clean
when trash plugs slots.
• Donotplaceanyitemsnexttoexhaustormuf-
fler to prevent burns or items from catching on fire
from high temperatures.
• Stopengineanddisconnectpowerifamalfunc-
tion occurs. Identify and resolve the malfunction
before turning machine on and resuming work.
2.6 PREPARATION SAFETY
• Neveroperatethegeneratorandauxiliaryequip-
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.
• Personalprotec-
tion equipment in-
cluding hard hat,
safety glasses,
safety shoes, and
gloves are recom-
mended during
assembly, instal-
lation, operation,
adjustment, main-
taining, repair-
ing,removal,ormovingthegenerator.Donotal-
low long hair, loose fitting clothing or jewelry to be
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
noise(fromtractors,chainsaws,radios,andother
suchsourcesclosetotheear)iscumulativeover
a lifetime without hope of natural recovery.
• Clearworkingareaofdebris,trashorhiddenob-
stacles that might be hooked or snagged, causing
injury, damage or tripping.
• Operateonlyindaylightorgoodartificiallight.
• Besuremachineisproperlyanchored,adjusted
and in good operating condition.
• Ensurethatallsafetyshieldingandsafetysigns
are properly installed and in good condition.
• Beforestarting,givethemachinea"onceover"for
any loose bolts, worn parts, cracks, leaks, frayed
belts and make necessary repairs. Always follow
maintenance instructions.

8
2.8 MAINTENANCE SAFETY
• Readandunderstandalltheinformationcontained
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.
• Followgoodshoppractices:
- Keep service area clean
and dry.
- Be sure electrical out-
lets and tools are properly
grounded.
- Use adequate light for the
job at hand.
• Makesureallguardsanddoorsareinplaceand
properly secured when operating the generator.
• Donotworkongeneratorelectri-
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.
• Afireextinguisherand
first aid kit should be kept
readily accessible while
performing maintenance
on this equipment.
• Disconnectloadfrompowersupplyandwaitfor
tall moving parts to stop before performing any
service or maintenance or work on them.
• Donottouchengine,manifold,pipesandmuffler
while engine is running. Allow engine to cool be-
fore performing any service work on it.
• Alwaysreplaceguardsandshieldsandclose
doors when service and repair work has been
completed.
• Donotremoveradiatorcapwhenengineisrun-
ning or still hot to prevent leaks and scalding
burns.
2.9 LOCK-OUT TAG-OUT SAFETY
• EstablishaformalLock-OutTag-Outprogramfor
your operation.
• Trainalloperatorsandservicepersonnelbefore
allowing them to work around the generator.
• Providetagsattheworksiteandasign-upsheet
to record tag out details.
• Donotserviceormaintainthegeneratorunless
motor is OFF and the power locked out with the
master switch.
2.10 BATTERY SAFETY
• Keepallsparksandflamesawayfrombatteries,
as gas given off by electrolyte is explosive. Always
wear gloves.
• Avoidcontactwithbatteryelectrolyte:washoffany
spilled electrolyte immediately.
• Wearsafetyglasseswhenworkingnearbatteries.
• Donottipbatteriesmorethan45°toavoidelectro-
lyte loss.
• Toavoidinjuryfromspark
or short circuit, disconnect
battery ground cable be-
fore servicing any part of
the electrical system.

9
2.11 OPERATING SAFETY
• ReadandunderstandtheOperator’sManualand
all safety signs before operating, maintaining, ad-
justing or repairing the generator.
• TurnmachineOFF,placemastercontrolsin
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.
• Keepallelectricalcomponentstight,dryandin
good repair.
• Cleartheareaofbystanders,especiallysmall
children.
• Replaceallwornorfailedcomponentsimmediate-
ly with megagen approved parts.
• Installandsecureallguardsbeforeoperating.
• Keephands,feet,hairandclothingawayfrom
moving parts.
• Reviewworksite.Positiongeneratortoprovide
electrical power accessibility and minimal interfer-
ence with other equipment.
• Theunitgeneratessufficientelectricalpowertoin-
jure or kill. Follow appropriate safety procedures.
• EstablishaformalLock-Out/Tag-Outprogramfor
your operation and train all operators and service
personnel before allowing them work with and
around the generator.
• RequireallpersonneltousePersonalProtective
Equipment(PPE)whenoperatingorservicingthe
machine.
• Donotstandorclimbonmachinewhenrunning.
Keep others off.
• Keeptheworkingareacleananddry.
• Reviewsafetyinstructionsannually.
2.12 TIRE SAFETY
• Failuretofollowproperprocedureswhenmount-
ing a tire on a wheel or rim can produce an explo-
sion which may result in serious injury or death.
• Donotattempttomountatireunlessyouhavethe
proper equipment and experience to do the job.
• Haveaqualifiedtiredealerorrepairserviceper-
form required tire maintenance.
• Whenreplacingworntires,makesuretheymeet
the original tire specifications. Never under-size.
2.13 TRANSPORT SAFETY
• Makecertainthatyouareincompliancewithlocal,
state/provincial and federal regulations regarding
transporting equipment on public roadways.
• Makecertainthatallwheelsandtiresareingood
repair and that tires are inflated to proper pressure.
Donotunder-inflateorover-inflate.
• Makecertainthatallwheelbolts/lugnutsaretight-
enedtopropertorquespecifications(refertospec-
ificationchartinSection7.2).
• Secureandlockaccessdoorsbeforetransporting.
• RaisejackintoitsfullyUPpositionandsecurewith
lock pin.
• Donotparkgeneratoronasteepslope.
• Besurethatanynecessarysigns,reflectorsand
lights required by law are in proper place and are
clearly visible to oncoming and overtaking traffic.
• Besurethatthegeneratorispositivelyhitchedto
the towing vehicle. Use a safety cable to assure a
safe hitch hook-up when transporting.
• Usea3/4tonpickuporlargertrucktotowmachine.
• Donotallowanyonetorideonthegeneratordur-
ing transport.
• Cleartheareaofobstaclesandunnecessary
personnel.
• Donotplaceanyobjectsorloadsontheframeto
prevent changing the center of gravity or overload-
ing the frame.
• Donotexceedasafetravelspeedof90km/55mph
with trailer. Slow down for corners and rough sur-
face conditions.
2.14 ELECTRICAL SAFETY
• Usetheterminalinsidetheframetogroundunitin
compliance with local laws and regulations.
• Allelectricalwires,plugs,socketsandothercom-
ponents must always be in good condition when
operating.
• Turnmasterbatteryandelectricalswitchesoff
when shutting down unit.
• Donotoperatemachinewithwethandsorclothing.

10
2.15 DIESEL ENGINE SAFETY
BEFORE STARTING ENGINE, READ AND UNDER-
STAND THE OPERATING AND MAINTENANCE IN-
STRUCTIONS THAT CAME WITH YOUR ENGINE.
WARNING: DO NOT
• DONOTrunengineinanenclosedarea.Exhaust
gases contain carbon monoxide, an odorless and
deadly poison.
• DONOTplacehandsorfeetnearmovingorrotat-
ing parts.
• DONOTstore,spill,orusefuelnearanopen
flame, or devices such as a stove, furnace, or wa-
ter heater which use a pilot light or devices which
can create a spark.
• DONOTrefuelindoorswhereareaisnotwellven-
tilated. Outdoor refuelling is preferred.
• DONOTfillfueltankwhileengineisrunning.Allow
enginetocoolfor5minutesbeforerefuelling.Store
fuel in approved safety containers.
• DONOTremovefueltankcapwhileengineis
running.
• DONOToperateengineiffuelisspilled.Move
machine away from the spill and avoid creating
any ignition until the fuel has evaporated.
• DONOTsmokewhenfillingfueltank.
• Wheneverpossible,graduallyreduceengine
speed before stopping.
• DONOTrunengineaboveratedspeeds.This
may result in injury.
• DONOTtamperwithpartswhichmayincrease
the governed engine speed.
• DONOTtamperwiththeenginespeedselected
by the original equipment manufacturer.
• DONOTstrikeflywheelwithahardobjectormetal
tool as this may cause flywheel to shatter in opera-
tion. Use proper tools to service engine.
• DONOToperateenginewithoutamuffler.Inspect
periodically and replace, if necessary. If engine is
equipped with muffler deflector, inspect periodical-
ly and replace, if necessary with correct deflector.
• DONOToperateenginewithanaccumulationof
grass, leaves, dirt or other combustible materials
in the muffler area.
• DONOTusethisengineonanyforestcovered,
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
theaboveisrequiredbylaw(Section4442ofthe
CaliforniaPublicResourcesCode).Otherstates
may have similar laws. Federal laws apply on fed-
eral lands.
• DONOTtouchhotmuffler,cylinderormanifold
because contact may cause burns.
• DONOTrunenginewithaircleaneroraircleaner
cover removed.
WARNING: DO
• ALWAYSdisconnectbatterybeforeservicingen-
gine to prevent accidental starting.
• DOexaminemufflerperiodicallytobesureitis
functioning effectively. A worn or leaking muffler
should be repaired or replaced as necessary.
• DOusefreshfuel.Stalefuelcangumfuelinjection
system.
• DOcheckfuellinesandfittingsfrequentlyfor
cracksorleaks.Replaceifnecessary.
2.16 REFUELLING SAFETY
• Handlefuelwithcare.Itishighlyflammable.
• Allowenginetocoolfor5minutesbeforerefuel-
ling. Clean up spilled fuel before restarting engine.
• Donotrefuelthemachinewhile
smoking or when near open flame or
sparks.
• Fillfueltankoutdoors.
• Preventfiresbykeepingmachine
clean of accumulated trash, grease
and debris.

11
2.17 REFILLING DEF SAFETY
Composition
DieselExhaustFluid(DEF)ismadefromamixtureof
purified water and urea. The formula is stable, color-
less, non-toxic, and similar to baking soda in its alka-
linity(pH).Itisnotafuel,butitisusedtoreducethe
level of nitrogen oxides in the exhaust to meet emis-
sions control standards.
Purpose
In the Selective Catalytic Reduction (SCR) system,
DEFisinjectedintotheexhaust.ItconvertstheNO2
into nitrogen gas and water vapor, which are harm-
less components of air.
Storing
The ideal temperature range for storing DEF is be-
tween32°Fand86°F,anditsaverageshelflifeis3
years.Keep DEF out of direct sunlight, and do not
store it in temperatures below 32°F.Because of its
alkalinity,DEFuidcancauseoxidizationinthesame
way that oxygen rusts raw steel, so it needs to be
stored in plastic or stainless steel containers.
What to know when filling your DEF tank
DEFtanksaredesignedsothattheopeningwillonly
accepta DEFfillnozzle.Astandardnozzlefordie-
sel fuel will not fitintotheDEFtankopening.This
safeguard ensures that only the proper fluid can be
pumped into the tank.
DEFtankswillholdbetween15and50gallons,de-
pending on the size and horsepower of your equip-
ment. Be sure to keep enough reserves on hand, as
equipmentwillceasetooperateoncetheDEFtank
is dry.
When to refill the tank
A DEF gauge has been added to most new equip-
ment that will show the fluid level and indicate when
it is time to refill.
WhentheDEFuidlevelreacheslessthan10%ca-
pacity, a series of warnings will alert the operator.
IftheDEFtankcontainslessthan5%ofitscapac-
ity, the equipment engine power will de-rate. The
DEFtankneedstobefilledonceforevery3to4
times that you refuel with diesel fuel. The frequency
will vary with operating conditions.