megagen

MODEL Z150 OPERATOR'S

MANUAL
 LIMITED megagen Z SERIES WARRANTY
This limited warranty is issued by megagen for the supply of the following products: megagen Z
Series Generators.

2 DESCRIPTION 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.

3 WARRANTY 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

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________________________ City, State/Prov., Code______________________

Phone Number ( _____ ) _ ___________________

Generator Model____________________________
Serial Number Alternator______________________

Unit Serial Number_ _________________________

Serial Number Engine________________________

Delivery Date_______________________________

DEALER INSPECTION REPORT SAFETY

______ Tire Pressure Checked (If on trailer) ______ Guards/Shields Installed & Secured
______ Wheel Bolts Torqued (If on trailer) ______ All Decals Installed & Legible
______ Inspect Electrical System ______ Safety Chain on Hitch (If on trailer)
______ Check Oil Level in Hydraulic Reservoir ______ Review Operating and Safety Instructions
______ Lubricate Machine
______ Check Engine Fluid Levels

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_________________________________

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.

z150

ENGINE ALTERNATOR

_ ___________________________

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 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.

1
2
2 SAFETY

SAFETY ALERT SYMBOL

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. Follow the instruc-
tions in the safety message.

Why is SAFETY important to you?

Accidents Disable and Kill

3 Big Reasons Accidents Cost You Money
Accidents Can Be Avoided

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
SIGNAL WORDS: guarded.
Note the use of the signal words DANGER,
WARNING and CAUTION with the safety
messages. The appropriate signal word for each
WARNING - Indicates a potentially hazardous situ-
ation that, if not avoided, could result
message has been selected using the following
in death or serious injury, and includes
guide-lines:
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.

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: 1-866-918-6976, Email: service@axiomequipmentgroup.
com.

3
 SAFETY 2.1 GENERAL SAFETY
YOU are responsible for the SAFE operation and • Read and understand the
maintenance of your megagen generator. YOU Operator's Manual and all safe-
must ensure that you and anyone else who is going ty signs before supplying pow-
to operate, maintain or work around the machine be er to, operating, maintaining or
familiar with the operating and maintenance proce- adjusting the generator.
dures and related SAFETY information contained in • Only trained, competent persons shall operate the
this manual. This manual will take you step-by-step generator. An untrained operator is not qualified to
through your working day and alerts you to all good operate this machine.
safety practices while operating the generator. • Provide a first-aid kit for use in case
of an accident. Store in a highly vis-
Remember, YOU are the key to safety. Good safety ible place.
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- • Provide a fire extinguisher for use in
erating this machine is familiar with the procedures case of an accident. Store in a highly
recommended and follows safety precautions. Re- visible place.
member, most accidents can be prevented. Do not • Install and properly secure all guards
risk injury or death by ignoring good safety practices. and shields before
operating.
• Read and understand the Operator's Manual
and all safety signs before supplying power to, • Wear appropriate
operating, maintaining or adjusting the generator. protective gear. This
• Generator owners must give operating instruc- list includes but
tions to operators or employees before allowing is not limited to:
them to operate the machine, and at least annu- - Protective shoes
ally thereafter. with slip resis-
• The most important safety device on this equip- tant soles
ment is a SAFE operator. It is the operator’s re- - Protective glasses
sponsibility to read and understand ALL Safety or goggles
and Operating instructions in the manual and to - Heavy gloves
follow these. Most accidents can be avoided. - Hearing protection
• A person who has not read and understood all op- • Turn machine OFF, place all controls in their OFF
erating and safety instructions is not qualified to position, shut down and lockout power supply,
operate this machine. An untrained operator ex- and wait for all moving parts to stop before servic-
poses himself and bystanders to possible serious ing, adjusting, maintaining, repairing or cleaning.
injury or death. • Do not damage this manual, do not remove or tear
• Do not modify the equipment in any way. any pages and keep it away from moisture and
Unauthorized modification may impair the func- heat sources. Please note that the drawings con-
tion and/or safety and could affect the life of the tained in the manual are merely to help you iden-
equipment. tify the parts described and, therefore, they might
• The manual comes with the original documen- not correspond precisely to your product.
tation for the engine and the alternator: we rec- • Know the emergency medical center number for
ommend keeping it all in a safe place and have your area.
qualified personnel to carry out operations. In • Review safety related items with all operators
case of transfer of equipment ownership, attach annually.
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.

4
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 prudence, and proper training of personnel in-
handling equipment. You, the operator, can avoid volved in the operation, transport, maintenance,
many accidents by observing the following pre- and storage of the machine. Refer also to Safety
cautions in this section. To avoid personal injury or Messages and operation instruction in each of the
death, study the following precautions and insist appropriate sections of the auxiliary equipment
those working with you, or for you, follow them. and machine Manuals. Pay close attention to the
• In order to provide a better view, certain photo- Safety Signs affixed to the auxiliary equipment
graphs or illustrations in this manual may show an and the machine.
assembly with a safety shield removed. However, • This machine is designed to generate high voltage
equipment should never be operated in this con- electrical power that can injure or kill if not oper-
dition. Keep all shields in place. If shield removal ated properly. Read operator's manual and follow
becomes necessary for repairs, replace the shield all instructions.
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.

5
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.
single careless act of an operator or bystander. • Replaced parts that displayed a safety sign should
• In addition to the design and configuration of also display the current sign.
equipment, hazard control and accident preven- • Safety signs displayed in Section 3 each have a
tion are dependent upon the awareness, con- part number in the lower right-hand corner. Use
cern, prudence and proper training of personnel this part number when ordering replacement
involved in the operation, transport, maintenance parts.
and storage of this equipment. • Safety signs are available from your authorized
• It has been said, "The best Distributor or Dealer Parts Department or the
safety feature is an informed, factory.
careful operator." We ask you
to be that kind of an operator. How to Install Safety Signs:
It is the operator's responsibility
to read and understand ALL Safety and Operating • Be sure that the installation area is clean and dry.
instructions in the manual and to follow these. • Be sure temperature is above 50°F (10°C).
Accidents can be avoided. • Determine exact position before you remove the
• Working with unfamiliar equipment can lead backing paper. (See Section 3).
to careless injuries. Read this manual, and the • Remove the smallest portion of the split backing
manual for your auxiliary equipment, before paper.
assembly or operating, to acquaint yourself • Align the sign over the specified area and careful-
with the machines. If this machine is used by ly press the small portion with the exposed sticky
any person other than yourself. It is the ma- backing in place.
chine owner's responsibility to make certain • Slowly peel back the remaining paper and care-
that the operator, prior to operating: fully smooth the remaining portion of the sign in
i. Reads and understands the operator's place.
manuals. • Small air pockets can be pierced with a pin and
ii. Is instructed in safe and proper use. smoothed out using the piece of sign backing
• Know your controls and how to stop generators paper.
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 2.5 STORAGE SAFETY
frequently with existing workers. Be certain only
a properly trained and physically able person will • Store the generator on a firm level surface.
operate the machinery. A person who has not read • If required, make sure the unit is firmly blocked up.
and understood all operating and safety instruc- • Make certain that all mechanical locks and jacks
tions is not qualified to operate the machine. An are safely and positively connected before storing.
untrained operator exposes himself and bystand- • Store away from areas of human activity.
ers to possible serious injury or death. If the elder- • Do not allow children to play on or around the
ly are assisting with work, their physical limitations stored generator.
need to be recognized and accommodated. • 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.

6
2.6 PREPARATION SAFETY 2.7 INSTALLATION SAFETY
• Never operate the generator and auxiliary equip- • Review layout of the worksite. Position generator
ment until you have read and completely un- where it can provide maximum power with mini-
derstand this manual, the auxiliary equipment mal interference with the access and operation of
Operator's Manual, and each of the Safety other equipment. Select a different position if there
Messages found on the safety signs on the gen- is interference.
erator and auxiliary equipment. • Position generator base or trailer on a solid, level
• Personal protec- surface to avoid tipping, sliding or falls during op-
tion equipment in- eration. Avoid placing the unit on a surface with a
cluding hard hat, slope of over 10°.
safety glasses, • Position machine so the engine exhaust is direct-
safety shoes, and ed away from personnel on the worksite. Direct the
gloves are recom- gases away from the worksite.
mended during • Use ground terminal inside frame to ground unit in
assembly, instal- compliance with local laws and regulations.
lation, operation, • Do not operate machine with wet hands or clothing.
adjustment, main- • All electrical wires, plugs, sockets and other com-
taining, repair- ponents must always be in good condition when
ing, removal, or moving the generator. Do not al- operating.
low long hair, loose fitting clothing or jewelry to be • Close and latch the doors during normal opera-
around equipment. tion. Open and latch the doors when the engine is
• PROLONGED EXPOSURE stopped and machine is being serviced.
TO LOUD NOISE MAY CAUSE • Keep engine cooling slots on doors and frame
PERMANENT HEARING LOSS! clean to allow engine to cool when running. Clean
Motors or equipment attached when trash plugs slots.
can often be noisy enough to • Do not place any items next to exhaust or muf-
cause permanent, partial hear- fler to prevent burns or items from catching on fire
ing loss. We recommend that you wear hearing from high temperatures.
protection on a full-time basis if the noise in the • Stop engine and disconnect power if a malfunc-
Operator's position exceeds 80db. Noise over tion occurs. Identify and resolve the malfunction
85db on a long-term basis can cause severe hear- before turning machine on and resuming work.
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.

7
2.8 MAINTENANCE SAFETY 2.10 BATTERY SAFETY
• Read and understand all the information contained • Keep all sparks and flames away from batteries,
in the Operator's Manual regarding operating, ser- as gas given off by electrolyte is explosive. Always
vicing, adjusting, maintaining and repairing. wear gloves.
• Turn machine OFF, shut down and lock out • Avoid contact with battery electrolyte: wash off any
power supply and wait for all moving parts to spilled electrolyte immediately.
stop before servicing, adjusting, maintaining • Wear safety glasses when working near batteries.
or repairing. • Do not tip batteries more than 45° to avoid electro-
• Follow good shop practices: lyte loss.
• To avoid injury from spark
- Keep service area clean or short circuit, disconnect
and dry. battery ground cable be-
- Be sure electrical out- fore servicing any part of
lets and tools are properly the electrical system.
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.

8
2.11 OPERATING SAFETY 2.13 TRANSPORT SAFETY
• Read and understand the Operator’s Manual and • Make certain that you are in compliance with local,
all safety signs before operating, maintaining, ad- state/provincial and federal regulations regarding
justing or repairing the generator. transporting equipment on public roadways.
• Turn machine OFF, place master controls in • Make certain that all wheels and tires are in good
their OFF position shut down and lock out power repair and that tires are inflated to proper pressure.
source, unplug power cord and wait for all moving Do not under-inflate or over-inflate.
parts to stop before servicing, adjusting, repairing • Make certain that all wheel bolts/lug nuts are tight-
or unplugging. ened to proper torque specifications (refer to spec-
• Keep all electrical components tight, dry and in ification chart in Section 7.2).
good repair. • Secure and lock access doors before transporting.
• 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.
ly with megagen 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.
moving parts. • Be sure that the generator is positively hitched to
• Review worksite. Position generator to provide the towing vehicle. Use a safety cable to assure a
electrical power accessibility and minimal interfer- safe hitch hook-up when transporting.
ence with other equipment. • Use a 3/4 ton pickup or larger truck to tow machine.
• The unit generates sufficient electrical power to in- • Do not allow anyone to ride on the generator dur-
jure or kill. Follow appropriate safety procedures. ing transport.
• Establish a formal Lock-Out/Tag-Out program for • Clear the area of obstacles and unnecessary
your operation and train all operators and service personnel.
personnel before allowing them work with and • Do not place any objects or loads on the frame to
around the generator. prevent changing the center of gravity or overload-
• Require all personnel to use Personal Protective ing the frame.
Equipment (PPE) when operating or servicing the • Do not exceed a safe travel speed of 90 km/55mph
machine. with trailer. Slow down for corners and rough sur-
• Do not stand or climb on machine when running. face conditions.
Keep others off.
• Keep the working area clean and dry.
• Review safety instructions annually.
2.14 ELECTRICAL SAFETY
• Use the terminal inside the frame to ground unit in
2.12 TIRE SAFETY compliance with local laws and regulations.
• All electrical wires, plugs, sockets and other com-
• Failure to follow proper procedures when mount- ponents must always be in good condition when
ing a tire on a wheel or rim can produce an explo- operating.
sion which may result in serious injury or death. • Turn master battery and electrical switches off
• Do not attempt to mount a tire unless you have the when shutting down unit.
proper equipment and experience to do the job. • Do not operate machine with wet hands or clothing.
• 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.

9
2.15 DIESEL ENGINE SAFETY
BEFORE STARTING ENGINE, READ AND UNDER- • DO NOT run engine with air cleaner or air cleaner
STAND THE OPERATING AND MAINTENANCE IN- cover removed.
STRUCTIONS THAT CAME WITH YOUR ENGINE.
WARNING: DO
WARNING: DO NOT
• ALWAYS disconnect battery before servicing en-
• DO NOT run engine in an enclosed area. Exhaust gine to prevent accidental starting.
gases contain carbon monoxide, an odorless and • DO examine muffler periodically to be sure it is
deadly poison. functioning effectively. A worn or leaking muffler
• DO NOT place hands or feet near moving or rotat- should be repaired or replaced as necessary.
ing parts. • DO use fresh fuel. Stale fuel can gum fuel injection
• DO NOT store, spill, or use fuel near an open system.
flame, or devices such as a stove, furnace, or wa- • DO check fuel lines and fittings frequently for
ter heater which use a pilot light or devices which cracks or leaks. Replace if necessary.
can create a spark.
• DO NOT refuel indoors where area is not well ven-
tilated. Outdoor refuelling is preferred. 2.16 REFUELLING SAFETY
• DO NOT fill fuel tank while engine is running. Allow
engine to cool for 5 minutes before refuelling. Store • Handle fuel with care. It is highly flammable.
fuel in approved safety containers. • Allow engine to cool for 5 minutes before refuel-
• DO NOT remove fuel tank cap while engine is ling. Clean up spilled fuel before restarting engine.
running. • Do not refuel the machine while
• DO NOT operate engine if fuel is spilled. Move smoking or when near open flame or
machine away from the spill and avoid creating sparks.
any ignition until the fuel has evaporated. • Fill fuel tank outdoors.
• DO NOT smoke when filling fuel tank. • Prevent fires by keeping machine
• Whenever possible, gradually reduce engine clean of accumulated trash, grease
speed before stopping. and debris.
• 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.

10
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 fluid 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 fluid 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.

11
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
be operating and/or maintaining a megagen built machine must read and clearly understand ALL Safety,
Operating and Maintenance information presented in this manual.

Do not operate or allow anyone else to operate this equipment until such information has been reviewed. Annu-
ally review this information before the season start-up.

Make these periodic reviews of SAFETY and OPERATION a standard practice for all of your equipment. We feel
that an untrained operator is unqualified to operate this machine.

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

12
3 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.

• Think SAFETY! Work SAFELY!

C
A

A B

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.

13
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. New safety signs are available from your authorized dealer.

14
4 OPERATION

OPERATING SAFETY
• Read and understand the Operator’s Manual • Review worksite. Position generator to provide
and all safety signs before operating, maintain- electrical power accessibility and minimal inter-
ing, adjusting or repairing the generator. ference with other equipment.
• Turn machine OFF, place master controls in • The unit generates sufficient electrical pow-
their OFF position shut down and lock out power er to injure or kill. Follow appropriate safety
source, unplug power cord and wait for all mov- procedures.
ing parts to stop before servicing, adjusting, re- • Establish a formal Lock-Out/Tag-Out program
pairing or unplugging. for your operation and train all operators and
• Keep all electrical components tight, dry and in service personnel before allowing them work
good repair. with and around the generator.
• Clear the area of bystanders, especially small • Require all personnel to use Personal Protective
children. Equipment (PPE) when operating or servicing
• Replace all worn or failed components immedi- the machine.
ately with megagen approved parts. • Do not stand or climb on machine when running.
• Install and secure all guards before operating. Keep others off.
• Keep hands, feet, hair and clothing away from • Keep the working area clean and dry.
moving parts. • Review safety instructions annually.

4.1 TO THE NEW OPERATOR OR OWNER

The megagen generator is designed to provide Follow all safety instructions exactly. Safety is
electrical power to areas where the power grid isn't everyone's business. By following recommended
available using a diesel engine as a power source. procedures, a safe working environment is pro-
vided for the operator, bystanders and the area
It is the responsibility of the owner or operator to around the worksite. Untrained operators are not
read this manual and to train all other operators qualified to operate the machine.
before they start working with the machine. In ad-
dition to the design and configuration of equip- Many features incorporated into this machine are the
ment, hazard control and accident prevention are result of suggestions made by customers like you.
dependent upon the awareness, concern, and Read this manual carefully to learn how to operate the
prudence of personnel involved in the operation, machine safely and how to set it to provide maximum
transport, maintenance and storage of equipment efficiency. By following the operating instructions in
or in the use of facilities. conjunction with a good maintenance program, your
megagen generator will provide many years of
trouble-free service.

15
4.2 MACHINE COMPONENTS
The 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. Load panels are mounted in
tems that require electric power in remote areas or the frame to maintain an engine load factor of more
where connecting to the grid is inconvenient, impos- than 30% to prevent wet stacking of the engine.
sible or not appropriate.
Five connections with breakers are available to con-
The engine, radiator, muffler, fuel tank, DEF tank are nect to 120V, 240V, 480V and 600V with various amp
all mounted inside the frame. Exhaust is direct out loadings and single and 3 phase outputs.
the top of the frame and away from the working area.
Fittings are provided to attach an auxiliary fuel tank A lift loop and a GPS sensor are mounted on top of
to the unit to provide longer running time between the frame as a convenience to the operator when re-
refuelling. The fuel tank is mounted under the engine quired.
and convenient to refuel. the alternator is mounted on
the flywheel housing to eliminate any drivetrain com- Slots and a screen on each end of the frame allow air
ponents. to flow through the frame to cool the engine and other
components.

A Left Side Frame

B Right Side Frame
C Deep Sea Controller
D AC Main Breaker
K
E Lug Connections
F Power Plug-Ins
G Engine Controller
B H Engine
J SCR Filter
K Exhaust
L GPS Sensor
M Lift Loop
N Alternator
O DEF Tank
P Battery
Q Load Bank Key Switch
R Master Electrical Switch
S Fuel Cap
T Fuel Tank
U Emergency stop
V Voltage Selector
W Auxiliary Fuel Intake
X Resistive Load Bank
Y Electrical Isolator
Z Auxiliary Fuel Selector

16 Fig. 1 MACHINE & tank COMPONENTS

 L
M

A D H

U
W

N O

G
Q
D

V
H
E

F F

K
H
J

S
Z
X

17
4.3 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 precautions and operating procedures contained in
items be checked: this section. Performing the following pre-operation
checklist is important for personal safety as well as
A. Read all manuals before starting including gen- for continued mechanical soundness and longevity
erator's engine and alternator. Follow break-in of your new megagen generator. The checklist
procedures. should be performed before operating the generator
and prior to each operation thereafter.
B. After 2, 5 and 10 hours of operation:
• Insure that proper
1. Retorque all bolts and fasteners. protective gear is in
good repair and avail-
2. Check that all electrical connections are able for use by each
tight and cords are routed out of the way or operator. Make cer-
protected. tain that each opera-
tor uses the protec-
3. Clean air flow screens. tive gear. Protective
gear includes but, is
4. Check levels in DEF tank and engine. Top up not limited to:
as required.
- Leather gloves
C. After 500 hours of operation: - Safety glasses or face shield
- Full length protective clothing
1. Change the engine oil and oil filter. Replace - Steel toed boots with slip resistant soles.
with recommended oil. - Hearing protection.

2. Then go to regularly scheduled service • Insure that all safety guards and shields are in
schedule. good repair and securely in place.
• Check that frame is level. Adjust as required.
• Make sure that all electrical switches are in the
OFF position before starting engine.
• Check that all electrical connections are tight
and cords are routed out of the way or protected.
• Be sure the working area is clean and dry to
prevent tripping or slipping.

18
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.
the operator to monitor a variety of engine and ma-
chine parameters. The module is designed to control h. Select Switch:
all machine functions and parameters. This centre switch confirms entries chosen in
the various edit menus and screens.
1. Control Unit:
DSE 7320 MKII: i. Main Breaker Switch:
Always refer to the manual provided with the unit Depress this switch to engage main breakers.
or refer to the unit on line for detailed instructions
on setting and operation of unit. j. Generator Breaker Control:
Depress this switch to engage generator
DSE 7320 MKII is an Auto start controller that breaker.
monitors the unit and indicates operational status
and fault conditions. The controller can be pro- k. System Display:
grammed to automatically start or stop based on Screen displays system parameters.
time schedule, fault condition or load demand.
l. OFF/ON Switch:
The controller constantly monitors vital genera- This 2 position rotary switch turns the system
tor and engine functions for a number of pre-pro- control feature OFF or ON.
grammed alarm and fault conditions. When a fault
condition occurs, the engine shuts down automat- m. Voltage Regulation:
ically and the LCD window shows the fault that This rheostat is used to adjust and set the
caused the shutdown. To resume operation, the generator output voltage by a small amount or
fault must be corrected. The controller records a fine tune it. Turn clockwise to increase voltage
history of unit performance, which may be viewed and counterclockwise to decrease.
at any time and will not be lost when the controller
is powered down. n. Load Bank Light:
This light comes on when the load bank sys-
2. Controller: tem is connected to the load circuit to prevent
a. Liquid Crystal Display (LCD) Window: wet stacking.
Displays the various operating screens. By
viewing these screens, the operator can moni-
tor both the engine and generator status while
the unit is running.
n
b. Menu Navigation: b a
Up/down and left/right triangles are used m
to navigate through the various operator
cd l
screens. They are also used to monitor and ef g 7
set the various machine parameters.

c. Stop/Reset Switch:
Depress to stop or reset controller or system. Fig. 2 DSE 7320 MKII Controller

d. Manual Mode:
Depress to place the controller into its manual
mode.

e. Auto Selector Switch:

Depress this switch to place the system into
its auto selector mode.
For further information please refer to DSE 7320 MKII available on
f. Alarm Mute Switch: https://www.deepseaelectronics.com/genset/lighting-tower-con-
Depress this switch to silence alarms. trol-modules/dse7320-mkii

19
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 4
switch and it will pop out and the unit can opera- 3
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.

4. AC Main Breaker:
This 2 position switch controls the electrical
power to the terminal lugs and the resistive load
bank. Turn fully clockwise to turn power on and Fig. 3 left side
counter clockwise to turn power off.

5. Curb Side Engine Door:

This 2 position rotary switch controls the elec-
trical power to the engine operating system. Turn
the switch clockwise to turn the system ON
and the engine will run. Turn the switch 1/4
turn counterclockwise to turn power to the en-
gine operating system OFF. Always turn the
engine system off when the unit is stopped for
the day, being serviced, stored or transported.
IMPORTANT
Before turning disconnect OFF, allow 5
minutes after engine shut down to al-
low the DEF system to purge to prevent Fig. 4 master engine disconnect
DEF line from fraying and bursting in
cold temperatures.

6. Power Outlet Receptacles:

The generator is equipped with 5 convenience 7
receptacles to provide power for customers.
Each outlet is designed with a circuit breaker to
prevent overloading. The 120V 20A outlets are
standard 3 prong receptacles. The 120V/240V
50A receptacles are the standard twist lock re- b
ceptacles. a
8
a. 120V 20A GFCI.

b. 120/240V Twist Lock 50A outlet. Fig. 5 outlets

7. USB Port:
This covered USB port is provided to service
personnel to use if it is necessary to access or
reprogram software for any reason. Covers the
port after the work is completed to prevent dirt
from entering the port.

8. Engine Block Heater:

This covered terminal is used to provide power
to the engine block heater and the battery char-
ger. Cover the terminal when the block heater is
unplugged.

20
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. Fig. 6 cables

c. Ground:
This is the earth ground for the generator.
Always connect this circuit to earth ground to
eliminate any stray currents.

10. Rear Compartment: a

a. Load Bank Switch:
This 2 position rotary switch controls the con-
nection to the machine load bank. The switch
must be turned to its On position for the load
b
bank to be connected when the unit starts
to maintain a load on the generator when
it starts. Turn the switch off when the unit is
stopped.

For the load bank to fully function, the Main Fig. 7 switches
breaker should be in the ON position to supply
power to the resistive load bank.

b. Voltage Selector:
This 4 position rotary switch selects the gen-
erator output voltage and phase output. The
options are:

• 347/600V 3 phase
• 277/480V 3 phase
• 208/240V 3 phase or 120/139V Single
phase
• 120/240V Single phase

11. Fuel Tank Selector:

This 2 position valve selects which fuel tank will be
used for the engine: internal or external. Move the
handle toward the left to draw from the internal and
to the right to draw from the external fuel source
using the external fuel connectors.

Fig. 8 fuel tank selector

21
4.6 MACHINE PREPARATION 4. Diesel Fuel:
Check the fuel level every day to prevent running
4.6.1 MECHANICAL PREPARATION: out. Since the unit can run for 38 to 42 hours with-
out refuelling under ideal conditions, the low fuel
1. Batteries: level alarm will sound on the display at 18% and
Batteries are an integral component in the suc- the machine will shut down at 10%.
cessful operation of the generator and must be
kept in top condition for the unit to perform as de- Turn engine off before refuelling.
signed. A starter battery is provided when the unit Do not smoke when refuelling
is new and is used to start the engine and keep all sparks and burning
. material away. Refuel outside or
in a well ventilated environment. Do not spill fuel.
a. Connect the cable to the Clean it up before starting. Refer to engine manual
battery terminal before for details on types of fuel to use in various tem-
starting the generator set. perature environments. Do not overfill tank. Leave
10 mm (1/2 inch) of space between level of fuel
b. Tighten battery pole clamp to its specified and top of tank to allow for fuel expansion. Use
torque. winter diesel or add special additives to fuel when
operating in cold temperatures.
c. Check the battery isolator if unit is equipped
with one. 5. Antifreeze/Coolant:
When the engine is new, it is filled with an anti-
d. Use rubber gloves when working with bat- freeze solution that is rated to -40° C. The anti-
teries as they contain sulphuric acid. Always freeze prevents both interior corrosion and protec-
rinse with large amounts of fresh water if con- tion against freezing. To maintain this protection,
tacting battery acid to prevent acid burns. It is do not mix different types of antifreeze. Refer to
recommended that the cable be disconnected engine operator's manual to determine the speci-
from the battery prior to transporting the unit. fications of the approved antifreeze.
If the cooling system requires ser-
2. Engine Oil: vicing, do not remove radiator cap
It is recommended that the en- when the engine is running or is
gine oil level be checked dai- still hot as the coolant could spill out abruptly and
ly to prevent running low and cause serious burns. Remove cap slowly and
damaging the engine. Refer to engine operator's carefully. Always maintain the integrity of the cool-
manual for detailed instructions and information ant overflow tank. It receives the excess coolant
on oil specification for varying operating environ- as the system heats up and expands. It provides
ments. Do not overfill crankcase. coolant into the radiator as the system cools and
contracts.
3. Air Filter:
Check the air filter canister when
the unit is new to verify it has a fil-
ter installed. Squeeze the rubber
flapper valve daily to remove any dirt that has ac-
cumulated. Open canister and remove filter if it
is dirty. Shake dirt out of filter. When operating
in dusty dirty conditions, it may be necessary to
clean the filter every few days. Replace filter after it
has been cleaned 4 or 5 times. Do not overclean.
Removing and installing the filter can damage
seals. Damaged seals can allow dust to enter the
engine and damage it.

22
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:

1. Lifting with hoist:

A bracket on the top of the machine is positioned
at the machine centre of gravity. This allows for
a hoist to raise the unit without the frame tilting.
Attach the hook on the hoist to the centre slot for
the best results.
Always use the hand grip when attaching hoist.
Hoist

2. Forklifts:
The frame is designed with 2 lateral pockets ex-
tending across the frame for lifting the machine.
Push the forks completely through the frame until
they extend out the other side to keep the machine
level and even when lifted. Raise slowly and raise
only as high as required.
Forklift Pockets
fig. 9 lifting

3. Tie Downs:
The frame is designed with slots on the bottom of
the frame for use to secure to frame when trans-
porting on a trailer. Do not attach to any other
place to tie down unit when transporting.

23
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. The differential switch guarantee protection
against indirect contact. If complex systems are con-
nected to the machine which require or use additional
electrical protective devices you must check the coor-
dination between the protective devices. Use the pre- Fig. 10 ground terminal
pared terminal to earth. Comply with local and/or cur-
rent regulations on installation and electrical safety.

4.6.4 POSITIONING:
Machine positioning and placement are important to
the functioning and reliability of the generator.

When positioning machine. follow this procedure:

1. Review the worksite and select an area where the

machine is out of the way and not interfere with the
other equipment on the worksite and yet provide
power to the required area.

2. Tow the machine to the selected spot (Refer to

Transport Section) if mounted on a trailer.
Fig. 11 positioned (typical)
3. Unhook from the tow vehicle.

4. Use a crane on hoist to lift generator off transport

vehicle and place on ground.

24
4.6.5 DSE 7320 MK11
The machine is designed with the DSEWebNet Gate-
way system used in conjunction with supported DSE
controllers to provide monitoring and communication
via the DSEWebNet advanced communication sys-
tem. The DSEWebNet Gateway communicates to a
maximum of 5 DSE controller(s) monitoring the in-
strumentation and operating state.

When this data changes, the new data is logged in the

internal memory. At regular intervals the logged data
is transmitted to the DSE hosted server. The DSE
hosted server is then integrated into the DSEWeb-
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, GPS and combined GSM & GPS
Antenna’s are available as standard on your Z150
generator.

You can easily download installation instruction

from: https://www.deepseaelectronics.com/genset/
remote-communications-overview-displays/dse7320

4.6.6 AUTOMATIC LOAD BANK

The unit is powered by a diesel engine. Diesel
engines are susceptible to wet stacking if lightly
loaded. Wet stacking can occur when an engine is
run at less than 30% of its full load capacity, causing
unburned fuel to accumulate in the engine. Wet
stacking can be detect-ed by continuous black
exhaust from the muffler when the unit is under a
constant load. It can also cause fouling of injectors
and buildup on engine valves. Die-sel engines
operate properly when applied loads are between
30% and 100% of system capacity. Our Z150
generator is equipped with an automatic load bank
in order to avoid wet stacking. Load bank will start
Fig. 12 load bank
au-tomatically after a few seconds. It will keep
running when engine load factor is less than 30%.
Once another load is connected, the load bank
will automatically turn OFF.

For the load bank to function properly, the

main breaker needs to be in the ON position.
When the load bank turns on the green indication
light next to the control panel will illuminate.

Load bank is functional only in 120/240V single

phase and 208/240V 3 Phase

25
4.7 OPERATION

OPERATING SAFETY
• Read and understand the Operator’s Manual • Review worksite. Position generator to provide
and all safety signs before operating, maintain- electrical power accessibility and minimal inter-
ing, adjusting or repairing the generator. ference with other equipment.
• Turn machine OFF, place master controls in • The unit generates sufficient electrical pow-
their OFF position shut down and lock out power er to injure or kill. Follow appropriate safety
source, unplug power cord and wait for all mov- procedures.
ing parts to stop before servicing, adjusting, re- • Establish a formal Lock-Out/Tag-Out program
pairing or unplugging. for your operation and train all operators and
• Keep all electrical components tight, dry and in service personnel before allowing them work
good repair. with and around the generator.
• Clear the area of bystanders, especially small • Require all personnel to use Personal Protective
children. Equipment (PPE) when operating or servicing
• Replace all worn or failed components immedi- the machine.
ately with megagen approved parts. • Do not stand or climb on machine when running.
• Install and secure all guards before operating. Keep others off.
• Keep hands, feet, hair and clothing away from • Keep the working area clean and dry.
moving parts. • Review safety instructions annually.

Follow this procedure when using the generator:

1. Move unit to work site and unhook or unload (refer

to Transport Section).

Fig. 13 machine (typical)

2. Chock the wheels if mounted on trailer.

3. Review Section 4.6 Machine Preparation and fol-

low all the instructions.

3. Review and follow the pre-operation checklist

(See Section 4.4).

4. Review the location and function of all controls

(See Section 4.5).

Fig. 14 chocks (typical)

26
5. Starting Steps:

a. Refer to and follow the machine

preparation and set-up sections. Be sure b
machine is lo-cated on a firm, level base.

b. Release the red e-stop switch by turning it

1/4 turn. c
c. Turn the battery isolator switch ON.

fig. 15 master power switch

d. Use the selector switch to select the voltage

and phase of the generator output desired.

Compartment

Voltage Selector Switch

e. Review the terminal connection specifications

and select the appropriate terminal.

f. Turn the key switch on.

Output Specs

Fig. 16 output selectors

27
 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.

Load Bank

fig. 18 no load

28
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.
Use the handle on the selector valve as an indica-
tor on which tank is being used:

a. Selector valve - Internal.

b. Selector valve - External. Selector Valve - External

c. Auxiliary tank couplers.

a
b

Selector Valve - Internal

Auxiliary Tank Couplers

fig. 19 fuel system

29
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.

• Always use Personal protective

Equipment (PPE) when operating or ser-
vicing machine.

b. Keep the area around the machine clean and

free from clutter to prevent ripping or slipping.

fig. 20 clean working area

c. Always attach doors to latch anchor behind

the door when it has been opened to prevent
closing from a gust of wind.

fig. 21 door latch

30
4.8 STORAGE
4.8 STORAGE
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.

4.8.1 PLACING IN STORAGE 4.8.2 REMOVING FROM STORAGE

At the end of the season, the machine should be thor- When preparing to use the machine at the start of the
oughly inspected and prepared for storage. Repair or season, follow this procedure:
replace any worn or damaged components to prevent
any unnecessary down time at the beginning of the • Transport or move to the working area.
next season. Follow this procedure: • Check

• Start the engine and run for 10 minutes to bring a. Engine fluid levels.
the oil to operating temperature. Change the oil
and oil filter. Replace the engine oil as specified in b. Electrical systems and components.
the Maintenance Section.
• Thoroughly wash the outside of the machine using c. All hardware. Tighten as required.
a pressure washer to remove all dirt, mud, debris
or residue. e. Air pressure in tires. Add as required.
• Do not wash the inside of the machine to pre-
vent getting water into the alternator and electrical • 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.
• Press the red switch on the DSE controller to turn
engine OFF.
• Turn main battery disconnect OFF.
• Touch up all paint nicks and scratches to prevent
rusting.
• Select a storage area that is dry, level and free of
debris.

fig. 22 stored
31
4.9 TRANSPORT

TRANSPORT SAFETY
• Make certain that you are in compliance with • Be sure that the generator is positively hitched to
local, state/provincial and federal regulations the towing vehicle. Use a safety cable to assure
regarding transporting equipment on public a safe hitch hook-up when transporting.
roadways. • Use a 3/4 ton pickup or larger truck to tow
• Make certain that all wheels and tires are in good machine.
repair and that tires are inflated to proper pres- • Do not allow anyone to ride on the generator
sure. Do not under-inflate or over-inflate. during transport.
• Make certain that all wheel bolts/lug nuts are • Clear the area of obstacles and unnecessary
tightened to proper torque specifications (refer to personnel.
specification chart in Section 7.2). • Do not place any objects or loads on the frame
• Secure and lock access doors before transporting. to prevent changing the center of gravity or over-
• Raise jack into its fully UP position and secure loading the frame.
with lock pin. • Do not exceed a safe travel speed of 90
• Do not park generator on a steep slope. km/55mph with trailer. Slow down for corners
• Be sure that any necessary signs, reflectors and and rough surface conditions.
lights required by law are in proper place and are
clearly visible to oncoming and overtaking traffic.

megagen Z150 generators are designed

and equipped to be towed on public roadways
when mounted on an megagen trailer by
vehicles with sufficient weight and braking capabilty.
If not mounted on trailer, they must be loaded on a
transport trailer and hauled.

Prepare the unit by:

• Press the red switch on the DSE controller to turn

engine OFF and turn key switch OFF.
• Turn main battery disconnect OFF.
• Remove any cords plugged into the machine.
• Hook up to tow unit.

a. Align hitches while backing up to hitch. Aligning

b. Connect pintle or ball hitch.

c. Secure hitch with retainer to prevent unex-

pected separation.

Retainer
fig. 23 pintle hitch

32
 d. Attach safety chains while crossing them un-
der the hitch.

Safety Chain - Attached

e. Attach wiring harness terminal.

Wiring Harness - Connected

f. 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.

i. Reverse this procedure when unhooking.

Jack Rotated/Handle Secured

• Check that all required lights are clean and no

bulbs are burned out.
• Do not drink or use drugs and drive.
• Do not allow riders on machine.
• Do not exceed a safe travel speed. Slow down for
corners or rough surfaces.

Hooked Up

fig. 24 transporting

33
34
5 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
repairing. 5.1 SERVICE
• Turn machine OFF, shut down and lock out
power supply and wait for all moving parts to 5.1.1 FLUIDS AND LUBRICANTS
stop before servicing, adjusting, maintaining
1. Grease:
or repairing.
Use an SAE multipurpose high temperature
• Follow good shop practices:
grease with extreme pressure (EP) performance.
Also acceptable is an SAE multipurpose lithium
- Keep service area clean and dry.
base grease.
- Be sure electrical outlets and tools are prop-
erly grounded.
2. Engine Oil:
- Use adequate light for the job at hand.
Refer to engine manual for oil specifications to use
• Make sure all guards and doors are in place and
with this engine. Consult the engine manual for
properly secured when operating the generator.
unusual operating conditions. Do not mix oil types
• Do not work on generator electrical system un-
or viscosities.
less the power cord is unplugged or the pow-
er supply is locked out. Lock-out tag-out power
Refer to engine manual for oil specifications
source before performing any maintenance
work.
3. Diesel Fuel:
• A fire extinguisher and first aid kit should be
Refer to engine manual for fuel specifications.
kept readily accessible while performing mainte-
Special fuel and additives required for cold
nance on this equipment.
ambients.
• Disconnect load from power supply and wait for
tall moving parts to stop before performing any
4. Storing Lubricants:
service or maintenance or work on them.
Your machine can operate at top efficiency only if
• Do not touch engine, manifold, pipes and muf-
clean lubricants are used. Use clean containers
fler while engine is running. Allow engine to cool
to handle all lubricants. Store them in an area pro-
before performing any service work on it.
tected from dust, moisture and other contaminants.
• 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.

35
5.1.2 SERVICING INTERVALS

8 Hours or Daily

1. 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

36
3. Remove dust from air cleaner flapper.

fig. 27 air cleaner

4. Clean air louvers.

In

Out
fig. 28 screens

37
100 Hours

1. 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

1. Remove the air cleaner filter and shake it out.

Replace filter after cleaning 5 times.

fig. 30 air cleaner (typical)

38
500 Hours or Annually

1. 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.

fig. 32 clean machine

39
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

As Required
CL Engine Air Cleaner

500 Hours or Annually

CH Engine Oil
CH Engine Oil Filter
CH Fuel Filter
CL Machine

1000 Hours or Annually

CH Engine Oil
CH Engine Oil Filter
CH Fuel Filter
CH Air Filter
CL Machine

40
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. By following a
careful service and maintenance program on your
machine, you will enjoy many years of trouble-free
use.

To maintain the integrity of each system and provide

a safe working environment for the operator, it is im-
portant that a daily inspection be done to make sure
that all systems and components are in good working
condition.

When inspecting the electrical system and compo-

nents, follow this procedure:

1. Place all controls in the OFF or neutral position.

2. Turn master electric switch OFF and lockout be-

fore starting the inspection.

3. Inspect all electrical components looking for:

a. Damaged receptacle.

b. Frayed or loose wires.

c. Cut or cracked insulation.

4. Replace any damaged components immediately.

5. Be sure all components are grounded.

6. Be sure there is not water or moisture in any junc-

tion box or enclosure. Dry the components before
turning power on. Be sure that all compartments
seal properly when closed.

41
5.2.2 CLEANING AIR CLEANER
1. 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.

7. Use a damp cloth to remove any dust and debris

from the filter housing. Shake the dust and dirt out
of the filter.
fig. 33 air cleaner
8. Install filter.

9. Install and secure cover.

10. Close and secure engine door.

42
5.2.3 CHANGING ENGINE OIL AND FILTER
1. 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

oil. Hot oil can cause burns if it contacts exposed
skin. It is best to change oil while the engine is a
warm to keep any contaminants in suspension.

6. Place a pan under the oil discharge hose.

7. Open drain valve and let drain until all oil is b

drained.

8. Remove the engine oil filter.

9. Apply a light coat of oil to the 'O' ring and install a. Filter b. Dipstick
the replacement filter. Snug up by hand and
then tighten to correct torque.

10. Close the drain valve and secure the drain hose.

11. Dispose of the used oil in an approved

container at a disposal site.

12. Fill the crankcase with specified oil.

13. Run the engine for 1 - 2 minutes and check for

oil leaks.

14. If leaks are found around the drain plug or

filter, tighten slightly. Fill Cap

fig. 34 ENGINE
15. Check engine oil level. Top up as required.

16. Close and secure engine access door.

43
5.2.4 CHANGING ENGINE FUEL FILTER AND WATER TRAP SCREEN FILTER
1. 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- c
posed skin. a

6. Place a pan under the fuel filter.

7. Loosen the hose clamps and remove fuel hoses

from screen filter.
b
8. Remove and replace screen filter.

9. Fit fuel hoses to screen filter and tighten hose

clamps.

10. To replace water trap fuel filter, disconnect water

trap sensor.
a. Fill Cap b. Oil Filter c. Fuel FIlter
11. Loosen filter.
fig. 35 ENGINE
12. Drain fuel from filter into a container.

13. Dispose of fuel in an environmentally safe manner.

14. Remove water trap sensor from old filter.

15. Remove old O-ring and fit new one on sensor.

16. Install water trap sensor onto new filter.

IMPORTANT
NEVER PRE-FILL fuel/water trap be-
fore installation as this may cause dam-
age to the fuel injection system. Prime
fuel filter using the prime valve on the
fuel filter housing until pressure is felt on
the prime button/pump.

17. Check engine fuel level. Top up as required.

18. Close and secure engine access door.

44
6 TROUBLE SHOOTING
The megagen Z150 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.

If you encounter a problem that is difficult to solve, even after having read through this trouble shooting
section, please contact your local megagen dealer or the factory. Before you call, please have this
Operator’s Manual from your machine ready.

PROBLEM CAUSE SOLUTION

Engine won't start. Low battery. Charge battery.
Emergency STOP switch engaged. Release STOP switch.
Start and stop (engine). No fuel. Fill fuel tank.
Bleed fuel lines.
Clogged fuel filter. Replace fuel filter.
Fuel circuit failure. Check fuel lines.
No generator output. Main circuit breaker open. Close main circuit breaker.
Voltage regulator malfunction. Call megagen Equipment group for
service.
Low oil pressure. Low oil level. Fill engine sump with oil.
Clogged oil filter. Replace oil filter.
Oil pump failure. Call megagen Equipment group for
service.
High coolant temperature. Electrical overload. Reduce load.
Low coolant level. Fill with coolant.
Low oil level. Fill sump with oil.
Clogged oil filter. Call megagen Equipment group for
service.

45
46
7 SPECIFICATIONS
7.1 MECHANICAL
The Z150 is a portable generator that can provide electrical power at any location. Please see data
sheet below and dimensional specifications as well.

SPECIFICATIONS Z150
Dimensions (L × W × H) (Skid) in 117.9 × 45 × 73.8

Operating Weight (Skid) lbs 6945

Prime Output kW (kVA) 120 (150)

Voltage V 240 / 480 / 600
Frequency Hz 60
Sound Level dBA 70
Battery V 24
Receptacles (2) 120V 20A
(3) 120V / 240V 50A
Engine Cummins QSB5-G12
Emissions T4F
Fuel Type Diesel
Tank Capacity gal (L) 187.5 (710)
Fuel Consumption Per Hour* gal/H (L/H) 6.3 (24)
Urea Tank Capacity gal (L) 15 (57)
Urea Consumption gal/H (L/H) 0.28 (1.08)
Runtime* hr 29.6

Gen End Mecc Alte

Trailer Mount Option Yes
Secondary Fluid Containment 110%

*At 75% load

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

47
48
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.

ENGLISH TORQUE SPECIFICATIONS

Bolt Torque*
Bolt
Diameter SAE 2 SAE 5 SAE 8
"A" (N.m) (lb-ft) (N.m) (lb-ft) (N.m) (lb-ft)
1/4" 8 6 12 9 17 12
5/16" 13 10 25 19 36 27
3/8" 27 20 45 33 63 45
7/16" 41 30 72 53 100 75
1/2" 61 45 110 80 155 115
9/16" 95 60 155 115 220 165
5/8" 128 95 215 160 305 220
3/4" 225 165 390 290 540 400
7/8" 230 170 570 420 880 650
1" 345 225 850 630 1320 970

METRIC TORQUE SPECIFICATIONS

Bolt Torque*
Bolt
Diameter 8.8 10.9
"A" (N.m) (lb-ft) (N.m) (lb-ft)
M3 .5 .4 1.8 1.3
M4 3 2.2 4.5 3.3
M5 6 4 9 7
M6 10 7 15 11
M8 25 18 35 26
M10 50 37 70 52
M12 90 66 125 92
M14 140 103 200 148
M16 225 166 310 229
M20 435 321 610 450
M24 750 553 1050 774
M30 1495 1103 575 1550
M36 2600 1917 3675 2710

Torque figures indicated above are valid for non-greased or non-oiled threads and heads unless otherwise
specified. Therefore, do not grease or oil bolts or capscrews unless otherwise specified in this manual. When
using locking elements, increase torque values by 5%.

* Torque value for bolts and capscrews are identified by their head markings.

49
1. Power Part

2. Power Switch

50
3. Voltage Regulator

4. Electronic Card Survey

51
5. Outputs Electronic Card

6. Analogic Inputs

52
7. Digital Inputs

8. Dummy Load

53
9. Auxiliary

10. Shutters

54
11. Modules

12. Terminal Board

55
13. Layout

56
14. Engine Schematic 1

57
58
15. Engine Schematic 2

59
60
16. Engine Schematic 3

61
62
8 INDEX
I S
PAGE PAGE
Introduction.......................................................1 Safety...............................................................3
Battery Safety.................................................8
Diesel Engine Safety....................................10
Electrical Safety..............................................9
O 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
Machine Break-In.........................................18 Preparation Safety..........................................7
Machine Preparation.....................................22 Refilling DEF Safety...................................... 11
Operation......................................................26 Refueling Safety...........................................10
Pre-Operation Checklist................................18 Safety Signs...................................................6
Storage.........................................................31 Safety Training................................................6
Transport.......................................................32 Sign-Off Form............................................... 11
Storage Safety................................................6
Tire Safety.......................................................9
Transport Safety..............................................9
Safety Sign Locations.....................................13
Service and Maintenance...............................35
Maintenance.................................................41
Service.........................................................35
Specifications.................................................47
Bolt Torque....................................................49
Electrical Schematic.....................................50
Mechanical...................................................47

Trouble Shooting.............................................45

63
64
megagen
Phone: 1 (866) 918-6976

[email protected]

PART NUMBER: 22859