MEGAGEN Z100 Operator's Manual
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MEGAGEN Z100 Operator's Manual

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MODEL Z 100 OPERATOR'S
MANUAL

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  • Page 1 MODEL Z 100 OPERATOR'S MANUAL...
  • Page 2 LIMITED Z SERIES WARRANTY megagen megagen This limited warranty is issued by for the supply of the following products: Series Generators. DESCRIPTION AND WARRANTY PERIOD megagen Machine: Without prejudice to the legal warranty, . 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).
  • Page 3 In no event will be liable for accidental, compensatory, consequential, indirect, special or megagen other damages. The liability of for a defect in the product will in any case be limited to the amount actually paid for that defective product.
  • Page 4 ELECTRIC POWER GENERATOR WARRANTY REGISTRATION FORM & INSPECTION REPORT 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 _______________________...
  • Page 6 SERIAL NUMBER LOCATIONS megagen Always give your dealer the serial number of your Z100 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. z100 ENGINE ALTERNATOR Model Z100 Serial Number...

  • Page 8: Table Of Contents

    TABLE OF CONTENTS SECTION DESCRIPTION PAGE Introduction ............1 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 ..........

  • Page 10: Introduction

    Safety, Operation, Maintenance and Trouble Shooting recommendations contained within this Operator's Manual. megagen This manual applies to all Z100 generators manufactured by . 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.

  • Page 12: Safety

    The Safety Alert symbol identifies This Safety Alert symbol means important safety messages on your ATTENTION! BECOME ALERT! megagen generator and in the YOUR SAFETY IS INVOLVED! manual. When you see this symbol, be alert to the possibility of personal injury or death.

  • Page 13: General Safety

    SAFETY 2.1 GENERAL SAFETY YOU are responsible for the SAFE operation and • Read and understand the megagen generator. YOU maintenance of your Operator's Manual and all safe- must ensure that you and anyone else who is going ty signs before supplying pow-...

  • Page 14: Equipment Safety Guidelines

    2.2 EQUIPMENT SAFETY GUIDELINES • Safety of the operator and bystanders is one of • In addition to the design and configuration of this the main concerns in designing and developing a implement, including Safety Signs and Safety machine. However, every year many accidents oc- Equipment, hazard control and accident preven- cur which could have been avoided by a few sec- tion are dependent upon the awareness, concern, onds of thought and a more careful approach to...

  • Page 15: Safety Training

    2.3 SAFETY TRAINING 2.4 SAFETY SIGNS • Safety is a primary concern in the design and man- • Keep safety signs clean and legible at all times. ufacture of our products. Unfortunately, our efforts • Replace safety signs that are missing or have be- to provide safe equipment can be wiped out by a come illegible.

  • Page 16: Preparation Safety

    2.7 INSTALLATION SAFETY 2.6 PREPARATION SAFETY • Review layout of the worksite. Position generator • Never operate the generator and auxiliary equip- where it can provide maximum power with mini- ment until you have read and completely un- mal interference with the access and operation of derstand this manual, the auxiliary equipment other equipment.

  • Page 17: Maintenance Safety

    2.10 BATTERY SAFETY 2.8 MAINTENANCE SAFETY • Keep all sparks and flames away from batteries, • Read and understand all the information contained in the Operator's Manual regarding operating, ser- as gas given off by electrolyte is explosive. Always vicing, adjusting, maintaining and repairing. wear gloves. •...

  • Page 18: Operating Safety

    Clear the area of bystanders, especially small • Raise jack into its fully UP position and secure with children. lock pin. • Replace all worn or failed components immediate- • Do not park generator on a steep slope. megagen ly with approved parts. • Be sure that any necessary signs, reflectors and • Install and secure all guards before operating. lights required by law are in proper place and are • Keep hands, feet, hair and clothing away from clearly visible to oncoming and overtaking traffic.

  • Page 19: Diesel Engine Safety

    2.15 DIESEL ENGINE SAFETY • DO NOT run engine with air cleaner or air cleaner BEFORE STARTING ENGINE, READ AND UNDER- cover removed. STAND THE OPERATING AND MAINTENANCE IN- STRUCTIONS THAT CAME WITH YOUR ENGINE. WARNING: DO WARNING: DO NOT • ALWAYS disconnect battery before servicing en- gine to prevent accidental starting. •...

  • Page 20: Refilling Def Safety

    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-...

  • Page 21: Sign-Off Form

    2.18 EMPLOYEE SIGN-OFF FORM megagen follows the general Safety Standards specified by the American Society of Agricultural and Bio- logical Engineers (ASABE) and the Occupational Safety and Health Administration (OSHA). Anyone who will megagen be operating and/or maintaining a built machine must read and clearly understand ALL Safety, Operating and Maintenance information presented in this manual.

  • Page 22: Safety Sign Locations

    SAFETY SIGN LOCATIONS 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 particu- lar function related to that area, that requires your SAFETY AWARENESS.
  • Page 23 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 particu- lar function related to that area, that requires your SAFETY AWARENESS. • Think SAFETY! Work SAFELY! REMEMBER - If Safety Signs have been damaged, removed, become illegible or parts replaced without safety signs, new signs must be applied.

  • Page 24: Operation

    • Require all personnel to use Personal Protective • Clear the area of bystanders, especially small children. Equipment (PPE) when operating or servicing • Replace all worn or failed components immedi- the machine. megagen • Do not stand or climb on machine when running. ately with approved parts. Keep others off. • Install and secure all guards before operating. • Keep the working area clean and dry. •...

  • Page 25: Machine Components

    4.2 MACHINE COMPONENTS megagen generator is a diesel engine pow- Batteries inside the frame provide power to start the ering an alternator to generate electricity. This elec- engine. All controls and electrical connections are on tricity is used to provide power to equipment or sys- the left side of the frame.

  • Page 27: Machine Break-In

    4.4 PRE-OPERATION CHECKLIST Although there are no operational restrictions on the Safe and efficient operation of your new generator re- megagen generator when used for the first time, quires that each operator reads and follows all safety it is recommended that the following mechanical...

  • Page 28: Controls

    4.5 CONTROLS It is recommended that all operators read the Deep g. Manual Start Switch: Sea Electronics module manual to learn how to oper- Depress this switch to initiate the engine start ate and navigate through the module features. Knowl- sequence providing there are no shutdown er- edge and understanding of this control module allows rors and the e-stop switch is released.
  • Page 29 3. Red Emergency Stop: This red switch is connected to a micro switch that sends a signal to the controller to shut do- wn the engine. Depress switch and the machine will stop. Turn the switch 1/4 turn to release the switch and it will pop out and the unit can opera- te. Switch must be out for unit to run. If switch was depressed due to an emergency or con- dition, correct condition before resuming work.
  • Page 30 9. Cable Outlets: a. L1, L2 and L3: Circuits L1, L2 and L3 are designed to pro- vide power to cables that are inserted from the bottom of the frame and secured with screw clamps. b. N: Use this connection as a ground for the ‘L’ circuits.

  • Page 31: Machine Preparation

    4.6 MACHINE PREPARATION 4. Diesel Fuel: Check the fuel level every day to prevent running out. Since the unit can run for 38 to 42 hours with- 4.6.1 MECHANICAL PREPARATION: out refuelling under ideal conditions, the low fuel Batteries: level alarm will sound on the display at 18% and the machine will shut down at 10%. Batteries are an integral component in the suc- cessful operation of the generator and must be kept in top condition for the unit to perform as de- Turn engine off before refuelling.
  • Page 32 4.6.2 HANDLING: The machine is designed with features that al- low it to be easily and conveniently moved, posi- tioned and transported. Three features are available to assist in handling: Lifting with hoist: A bracket on the top of the machine is positioned at the machine centre of gravity.
  • Page 33 4.6.3 ELECTRICAL PREPARATION: Every operator should review the operator's manuals from the engine, Deep Sea Electronics and alterna- tor manufacturers provided in the document package. Follow the detailed instructions in each manual: Connect the neutral point of the generator set to the machine ground. By using the TN or TT distribution system.
  • Page 34 Net® which can be accessed via an internet connect- ed device and web browser to allow remote monitor- ing and control of multiple DSE controllers worldwide. GSM, combined & Antenna’s are available as standard on your Z100 generator. You can easily download installation instruction from: https://www.deepseaelectronics.com/genset/ remote-communications-overview-displays/dse7320 4.6.6 AUTOMATIC LOAD BANK...

  • Page 35: Operation

    • Require all personnel to use Personal Protective • Clear the area of bystanders, especially small children. Equipment (PPE) when operating or servicing • Replace all worn or failed components immedi- the machine. megagen • Do not stand or climb on machine when running. ately with approved parts. Keep others off. • Install and secure all guards before operating. • Keep hands, feet, hair and clothing away from •...
  • Page 36 5. Starting Steps: a. Refer to and follow the machine preparation and set-up sections. Be sure machine is lo-cated on a firm, level base. b. Release the red e-stop switch by turning it 1/4 turn. c. Turn the battery isolator switch ON. FIG.
  • Page 37 g. Depress the white switch with the finger to set system into manual mode. FIG. 17 ISOLATOR SWITCH h. Depress the green engine start switch to initiate the engine start sequence. i. Wait until the engine stabilizes. j. Set voltage with potentiometer to desired voltage. Controls k. If external load is less than 30%, the load bank will set in and the load bank light will come ON.
  • Page 38 11. Fuel Tank Selector: The generator is designed with an internal fuel tank that comes from the factory and is plumbed into the engine. In addition a set of fuel connec- tions are provided on the left side of the frame that allow the operator to connect an auxiliary tank to provide longer operating time between refuelling.
  • Page 39 11. Operating Hints: a. The machine is designed to generate a large amount of electrical power that can injure, maim and kill if not handled with care. • Always stop engine, place all controls in their off position and wait for all moving parts to stop before servicing, maintain- ing, adjusting or cleaning machine.

  • Page 40: Storage

    • Replace any defective components. circuits. • Go through the pre-operation checklist (section • If stored on an megagen trailer, lower hitch jack 4.4) before starting. and secure. • Place chocks in front of and behind wheels if mounted on trailer. •...

  • Page 41: Transport

    capabilty.
  • Page 42 d. Attach safety chains while crossing them un- der the hitch. Safety Chain - Attached e. Attach wiring harness terminal. Wiring Harness - Connected Raise the hitch jack into its fully UP position. g. Rotate jack and pin in its horizontal position. h. Secure jack handle with its retainer. Reverse this procedure when unhooking. Jack Rotated/Handle Secured • Check that all required lights are clean and no bulbs are burned out.

  • Page 44: Service And Maintenance

    SERVICE AND MAINTENANCE MAINTENANCE SAFETY • Read and understand all the information con- tained in the Operator's Manual regarding op- erating, servicing, adjusting, maintaining and SERVICE repairing. Turn machine OFF, shut down and lock out • 5.1.1 FLUIDS AND LUBRICANTS power supply and wait for all moving parts to stop before servicing, adjusting, maintaining Grease:...
  • Page 45 5.1.2 SERVICING INTERVALS 8 Hours or Daily Check engine fluid levels: a. Fuel b. Crankcase oil c. Coolant Fuel Cap Dipstick Coolant FIG. 25 FLUID LEVELS 2. Check DEF tank fluid level. FIG. 26 DEF TANK...
  • Page 46 3. Remove dust from air cleaner flapper. FIG. 27 AIR CLEANER 4. Clean air louvers. FIG. 28 SCREENS...
  • Page 47 100 Hours Change break-in engine oil and oil filter. This ser- vice item only must be done once when unit is new. Then service every 500 hours. Follow the service schedule outlined in the engine manufac- turer's manual. FIG. 29 OIL FILTER As Required Remove the air cleaner filter and shake it out.
  • Page 48 500 Hours or Annually Change fuel filter. a. Engine oil. b. Oil filter. c. Fuel filter. d. Air filter. FIG. 31 FUEL FILTER 2. Clean machine. IMPORTANT Never pressure wash near the alterna- tor end as it may cause electrocution or catastrophic failure of major compo- nents.
  • Page 49 5.1.3 SERVICE RECORD See Lubrication and Maintenance sections for details of service. Copy this page to continue record. ACTION CODE: CL CLEAN CK CHECK R REPACK CH CHANGE Maintenance Hours Serviced by 8 Hours or Daily CK Engine Fluid Levels CK DEF Tank CL Air Cleaner Flapper CL Air Screens 100 Hours CH Break-In Engine Oil and Filter...

  • Page 50: Maintenance

    5.2 MAINTENANCE The machine is designed to generate electricity for use at any location for any purpose. By following a careful service and maintenance program on your machine, you will enjoy many years of trouble-free use. 5.2.1 ELECTRIC SYSTEM INSPECTION The machine is designed to generate electricity for use at any location for any purpose.
  • Page 51 5.2.2 CLEANING AIR CLEANER Review the operator's manual for the engine. 2. Place all controls in the OFF or neutral position. 3. Turn OFF battery disconnect. 4. Open engine door. 5. Remove cover over air cleaner. 6. Remove the filter from the air cleaner. Use a damp cloth to remove any dust and debris from the filter housing. Shake the dust and dirt out of the filter.
  • Page 52 5.2.3 CHANGING ENGINE OIL AND FILTER Review the operator's manual for the engine. Place all controls in the OFF or neutral position. Turn OFF battery disconnect. Open engine door. Allow the engine to cool before changing the oil. Hot oil can cause burns if it contacts exposed skin. It is best to change oil while the engine is warm to keep any contaminants in suspension.
  • Page 53 5.2.4 CHANGING ENGINE FUEL FILTER AND WATER TRAP SCREEN FILTER Review the operator's manual for the engine. 2. Place all controls in the OFF or neutral position. 3. Turn OFF battery disconnect. 4. Open engine door. 5. Allow the engine to cool before changing the fuel filter. Hot fuel can cause burns if it contacts ex- posed skin.

  • Page 54: Trouble Shooting

    TROUBLE SHOOTING megagen Z100 generator is a machine with an alternator and controls to generate single or 3 phase power at 4 different power levels. A diesel engine provides power to generate electricity. In the following section, we have listed many of the problems, causes and solutions to the problems that you may encounter.

  • Page 56: Specifications

    SPECIFICATIONS 7 .1 MECHANICAL The Z100 is a portable generator that can provide electrical power at any location. Please see data sheet below and dimensional specifications as well. SPECIFICATIONS Z100 Dimensions (L × W × H) (Skid) 117.9 × 45 × 73.8...

  • Page 58: Bolt Torque

    7 .2 BOLT TORQUE CHECKING BOLT TORQUE The tables shown below give correct torque values for various bolts and capscrews. Tighten all bolts to the torques specified in chart unless otherwise noted. Check tightness of bolts periodically, using bolt torque chart as a guide. Replace hardware with the same strength bolt.

  • Page 59: Electrical Schematic

    1. Power Part 2. Power Switch...

  • Page 60: Index

    3. Voltage Regulator 4. Electronic Card Survey...
  • Page 61 5. Outputs Electronic Card 6. Analogic Inputs...
  • Page 62 7. Digital Inputs 8. Dummy Load...
  • Page 63 9. Auxiliary 10. Shutters...
  • Page 64 11. Modules 12. Terminal Board...
  • Page 65 13. Layout...
  • Page 66 14. Engine Schematic 1...
  • Page 68 15. Engine Schematic 2...
  • Page 70 16. Engine Schematic 3...
  • Page 72 INDEX PAGE PAGE Introduction ............1 Safety ..............3 Battery Safety ..........8 Diesel Engine Safety ........10 Electrical Safety ..........9 Equipment Safety Guidelines ......5 General Safety ..........4 Operation ............15 Installation Safety ..........7 Controls ............19 Lock-Out Tag-Out Safety .......8 To the New Operator or Owner ....15 Maintenance Safety ........8 Machine Components ........16 Operating Safety ..........9...
  • Page 75 Phone: 1 (866) 918-6976 service@axiomequipmentgroup.com PRINTED IN CANADA REVISION DATE: OCTOBER 2023 PART NUMBER: 22859...

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