Magnum 6500 Specifications

Magnum 6500 Specifications
DRY-PRIME DIESEL TRASH PUMP
MTP6500FH
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OPERATING MANUAL
INTRODUCTION
This manual provides information and procedures to safely operate and maintain the engine and pump. For your
own safety and protection from physical injury, carefully read, understand, and observe the safety instructions
described in this manual. The information contained in this manual was based on machines in production at the time
of publication. Magnum Products LLC reserves the right to change any portion of this information without notice.
DO NOT MODIFY or use this equipment for any application other than which it was designed for.
Magnum Products LLC recommends that a trained and licensed professional perform all electrical wiring and testing
functions. Any wiring should be in compliance with the United States National Electric Code (NEC), state and local
codes and Occupational Safety and Health Association (OSHA) guidelines.
Keep a copy of this manual with the unit at all times. Additional copies are available from Magnum Products LLC, or
can be found at www.m-p-llc.com. An Engine Operators Manual was also supplied with the unit at the time of
shipment from the factory. The manual provides detailed operation and maintenance procedures for the engine.
Additional copies of the engine operators manual are available from the engine manufacturer.
MAGNUM PRODUCTS LLC
215 Power Drive • Berlin, WI 54923
U.S.A.
Phone: 920-361-4442
FAX: 920-361-4416
Toll Free: 1-800-926-9768
www.m-p-llc.com
For technical or parts QUESTIONS, please contact Magnum Products’ Customer Support or
Technical Support team at 920-361-4442. Please have your serial number available.
To ORDER SERVICE PARTS, please contact the dealer from which you purchased the unit, or call
Magnum Products to locate a dealer in your area.
Engine Make:__________________________________________
Engine Serial Number:___________________________________
Engine Model Number: __________________________________
Pump Make:___________________________________________
Pump Model Number: ___________________________________
Pump Serial Number: ___________________________________
Unit Model Number:_____________________________________
Unit Serial Number: _____________________________________
WARNING
CALIFORNIA PROPOSITION 65 WARNING: Diesel engine exhaust and some of its
constituents are known to the state of California to cause cancer, birth defects and
other reproductive harm.
2
TABLE OF CONTENTS
Page
INTRODUCTION ............................................................................................................................... 2
TABLE OF CONTENTS ..................................................................................................................... 3
SAFETY NOTES ............................................................................................................................... 4
OPERATING SAFETY ....................................................................................................................... 4
ENGINE SAFETY .............................................................................................................................. 5
SERVICE SAFETY ....................................................................................................................... 5 - 6
TOWING SAFETY ............................................................................................................................. 6
REPORTING TRAILER SAFETY DEFECTS .................................................................................... 6
SAFETY SYMBOL SUMMARY ......................................................................................................... 7
UNIT SERIAL NUMBER LOCATIONS .............................................................................................. 7
LOCATIONS & CONTROLS ......................................................................................................... 8 - 9
SPECIFICATIONS ........................................................................................................................... 10
FRONT HOOD OPERATION .......................................................................................................... 11
REAR HOOD OPERATION ...................................................................................................... 12 - 13
MAIN CONTROL PANEL COMPONENTS ..................................................................................... 14
CONTROL PANEL LEDS ................................................................................................................ 15
PRE-USE CHECKPOINTS .............................................................................................................. 16
PUMP SET UP ................................................................................................................................ 16
STARTING THE PUMP ............................................................................................................ 17 - 18
SUCTION SPECIFICATIONS .......................................................................................................... 18
STOPPING THE PUMP .................................................................................................................. 19
AUTOMATIC SHUTDOWN .............................................................................................................. 19
REMOTE/AUTO STARTING ........................................................................................................... 19
ENGINE AND PUMP MAINTENANCE ........................................................................................... 19
ENGINE BREAK-IN REQUIREMENTS ........................................................................................... 19
PUMP BEARING FRAME LUBRICATION ...................................................................................... 20
MECHANICAL SEAL LUBRICATION .............................................................................................. 20
DAILY WALK AROUND INSPECTION ............................................................................................ 21
BELT TENSION ............................................................................................................................... 21
MAINTENANCE SCHEDULE ................................................................................................... 21 - 22
TOWING THE TRAILER ................................................................................................................. 22
TRAILER WHEEL BEARINGS ........................................................................................................ 22
LIFTING THE PUMP ....................................................................................................................... 23
PUMP TROUBLESHOOTING ......................................................................................................... 24
ENGINE FAULT SHUTDOWN TROUBLESHOOTING ................................................................... 25
TRAILER LIGHTS WIRING DIAGRAM ............................................................................................ 26
DC WIRING DIAGRAM ................................................................................................................... 27
3
SAFETY NOTES
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible injury or death.
This manual contains DANGERS, WARNINGS, CAUTIONS, NOTICES and NOTES which must be
followed to prevent the possibility of improper service, damage to the equipment, personal injury or death.
The following formatting options will apply when calling the readers attention to the DANGERS, WARNINGS, CAUTIONS, NOTICES and NOTES.
DANGER
INDICATES A HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN
DEATH OR SERIOUS INJURY.
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION
Indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.
Indicates a hazardous situation which, if not avoided, may result in property or equipment
damage.
Note: Notes contain additional information important to a procedure and will be found within the regular text body
of this manual.
OPERATING SAFETY
Before using the pump be sure you read and understand all of the instructions! This equipment was
designed for specific applications; DO NOT modify or use this equipment for any application other than
which it was designed for. Equipment operated improperly or by untrained personnel can be dangerous!
Read the operating instructions and familiarize yourself with the location and proper use of all instruments
and controls. Inexperienced operators should receive instruction from someone familiar with the equipment
before being allowed to operate or set up the pump. The following points should be practiced at all times:
4
•
The area immediately surrounding the pump should be dry, clean, and free of debris.
•
Position and operate pump on a firm, level surface.
•
NEVER start a unit in need of repair.
•
NEVER modify the pump or use it in a manner other than for what it was designed.
•
Do not start the pump if any panels or guards are loose or missing.
•
Move the engine start switch to the “OFF” position when servicing or troubleshooting.
•
Use hearing protection if you will be near an operating pump for an extended period of time.
•
Keep clear of pump suction and discharge openings while pump engine is running.
ENGINE SAFETY
Internal combustion engines present special hazards during operation and fueling! Failure to follow the
safety guidelines described below could result in severe injury or death. Also read and follow all safety
warnings described in the Engine Operators Manual. A copy of this manual was supplied with unit when
it was shipped from the factory.
•
DO NOT run engine indoors or in an area with poor ventilation unless exhaust hoses are used. Diesel
engine exhaust contains carbon monoxide, a deadly, odorless and colorless gas which, if inhaled,
can cause nausea, fainting or death. Make sure engine exhaust cannot seep into closed rooms or
ventilation equipment.
•
DO NOT fill fuel tank near an open flame, while smoking, or while engine is running. DO NOT fill tank
in an enclosed area with poor ventilation.
•
DO NOT operate with the fuel tank cap loose or missing.
•
DO NOT operate on a combustible surface.
•
DO NOT touch or lean against hot exhaust pipes or engine block.
•
DO NOT clean air filter with gasoline or other types of low flash point solvents.
•
DO NOT remove engine coolant cap while engine is hot.
•
DO NOT operate the unit without a functional exhaust system. Prolonged exposure to sound levels
in excess of 85 DBA can cause permanent hearing loss. Wear hearing protection when working around
a running engine.
•
Keep hands, feet and loose clothing away from moving parts on the pump and engine.
•
Keep area around exhaust pipes and radiator free of debris to reduce the chance of an accidental fire.
•
Batteries contain sulfuric acid which can cause severe injury or death. Sulfuric acid can cause eye
damage, burn flesh or eat holes in clothing. Protective eye wear and clothing are necessary when
working on or around the battery. Always disconnect the NEGATIVE (-) battery cable from the
corresponding terminal before performing any service on the engine or other components.
•
Shut down the engine if any of the following conditions exist during operation:
1.
Noticeable change in engine speed.
2.
Loss of pumping output.
3.
Sparking occurs.
4.
Engine misfires or there is excessive engine/pump vibration or noise.
SERVICE SAFETY
Only a qualified electrician should troubleshoot or repair electrical problems occurring in this equipment.
•
Before servicing the trash pump, make sure the engine start switch is turned to OFF and the negative
terminal on the battery is disconnected. NEVER perform even routine service (oil/filter changes,
cleaning, etc.) unless all electrical components are shut down.
•
NEVER service electrical components if clothing or skin is wet. If the unit is stored outside, check the
engine for any moisture and dry the unit before use.
•
NEVER open the radiator cap or oil drain plug while the engine is running or before the engine has
cooled down. Pressurized coolant and hot engine oil can cause severe burns. Allow the engine to
cool completely before attempting any service work.
•
NEVER attempt to modify the engine, pump or related components.
•
NEVER wash the unit with a power washer or high pressure hose.
•
Keep hands, feet, hair and loose clothing away from moving parts.
•
Replace all guards and safety devices immediately after servicing.
5
•
Replace all missing and hard-to-read labels. Labels provide important operating instructions and warn
of dangers and hazards.
•
Make sure slings, chains, hooks, ramps, jacks, and other types of lifting devices are attached securely
and have enough weight-bearing capacity to lift or hold the equipment safely. Always remain aware
of the position of other people around you when lifting the equipment.
TOWING SAFETY
Towing a trailer requires care! Both the trailer and vehicle must be in good condition and securely fastened
to each other to reduce the possibility of an accident. Also, some states require that large trailers be
registered and licensed. Contact your local Department of Transportation office to check on license
requirements for your particular unit.
•
Check that the hitch and coupling on the towing vehicle are rated equal to, or greater than, the trailer's
“gross vehicle weight rating” (GVWR).
•
Check tires on trailer for tread wear, inflation, and condition.
•
Inspect the hitch and coupling for wear or damage. DO NOT tow trailer using defective parts!
•
Make sure the trailer hitch and the coupling are compatible. Make sure the coupling is securely fastened
to the vehicle.
•
Connect safety chains in a crossing pattern under the tongue and attach the breakaway cable TO
THE REAR BUMPER OF THE TOWING VEHICLE. Do not attach the cable to the trailer hitch.
•
Make sure directional and brake lights on the trailer are connected and working properly.
•
Check that all lug nuts holding wheels on are tight and that none are missing.
•
Maximum recommended speed for highway towing is 45 m.p.h. Recommended off-road towing speed
is not to exceed 10 m.p.h. or less depending on terrain.
The trailer is equipped with hydraulic surge brakes or electric surge brakes. Check the operation of the
brakes by braking the vehicle at a slow speed before entering traffic. Both the trailer and the vehicle should
brake smoothly. If the trailer seems to be pushing, check the level in the surge brake fluid reservoir.
When towing, maintain extra space between vehicles and avoid soft shoulders, curbs and sudden lane
changes. If you have not pulled a trailer before, practice turning, stopping, and backing up in an area away
from heavy traffic.
A film of grease on the coupler will extend coupler life and eliminate squeaking. Wipe the coupler clean
and apply fresh grease each time the trailer is towed.
REPORTING TRAILER SAFETY DEFECTS
If you believe your trailer has a defect which could cause a crash or could cause injury or death, you should immediately
inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Magnum Products LLC.
If NHTSA receives similar complaints, it may open an investigation; and if it finds that a safety defect exists in a group
of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual
problem between you, your dealer, or Magnum Products LLC.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-888-327-4236 (TTY:1-800-424-9153),
go to http://www.safercar.gov; or write to:
Administrator
NHTSA
1200 New Jersey Avenue S.E.
Washington, DC 20590
You can also obtain other information about motor vehicle safety from http://www.safercar.gov.
6
SAFETY SYMBOL SUMMARY
This equipment has been supplied with numerous safety and operating decals. These decals provide important
operating instructions and warn of dangers and hazards. Replace any missing or hard-to-read decals and use care
when washing or cleaning the unit. Decal placement and part numbers can be found in the parts manual. Below is
a summary of the intended meanings for the symbols used on the decals.
Safety alert symbol; Used to
alert you to potential personal
injury hazards.
Asphyxiation hazard; Operate
in well ventilated area.
Hot surface(s) nearby.
Hazardous voltage. Disconnect
battery before servicing.
Belt/entanglement hazard; Keep
body parts clear of this area.
Anchor/tie down point.
Rotating fan hazard; do not operate
without guards in place. Keep body
parts clear of this area.
Burn/scald hazard;
pressurized steam.
Rotating impeller blade hazard;
Keep body parts clear of this area.
Use clean diesel fuel only.
Moving parts can crush and cut;
Keep body parts clear of this area.
Remove negative battery
cable before performing
any service on unit.
Stop engine before fueling.
Read and understand the
supplied operating manual
before operating unit.
Hearing protection required
while operating unit.
Lift here only.
Fire/explosion hazard; Keep
open flames away from unit.
Crush/pinch hazard; Keep
body parts clear of this area.
UNIT SERIAL NUMBER LOCATIONS
Unit ID Tag
V.I.N. Tag
MANUFACTURED BY/FABRIQUE PAR: MAGNUM PRODUCTS LLC
GVWR/PNBV:
GAWR/PNBE
Refer to the locations illustrated to find the unit ID tag, and
trailer ID tag on your unit. Important information, such as
the unit serial number, model number and Vehicle Identification Number (V.I.N.) for your trailer are found on these
tags. Record the information from these tags, so it is
available if the tags are lost or damaged. When ordering
parts or requesting technical service assistance, you will
be asked to specify this information.
MODEL
MTP6500FH/STD
SERIAL NUMBER
000000
kg
lbs
MADE IN USA 0000
0000
TIRE/PNEU
RIM/JANTE
THIS VEHICLE CONFORMS TO ALL APPLICABLE STANDARDS PRESCRIBED UNDER THE
CANADIAN MOTOR VEHICLE SAFETY REGULATIONS IN EFFECT ON THE DATE OF
MANUFACTURE. / CE VEHICULE EST CONFORME A TOUTES LES NORMES QUI LUI
SONT APPLICABLES EN VERTU DU REGLEMENT SUR LA SECURITE DES VEHICULES
AUTOMOBILES DU CANADA EN VIGUEUR A LA DATE SA FABRICATION.
V.I.N./N.I.V.:
00000000000000000
DATE: 00/0000
COLD INFL. PRESS./PRESS.
DE GONF A FROID
SGL/DUAL
KPA(PSI/LPC)
TYPE/TYPE DE VEHICULE:
THIS VEHICLE CONFORMS TO ALL
APPLICABLE U.S. FEDERAL MOTOR
VEHICLE SAFETY STANDARDS
(FMVSS) IN EFFECT ON THE DATE
OF MANUFACTURE SHOWN ABOVE.
TRAILER MTG
Trailer ID Tag
MAGNUM PRODUCTS LLC
BERLIN, WI 54923 USA
(800) 926-9768
MODEL
MTG55F/STD
SERIAL NUMBER
000000
kg
lbs
MADE IN USA 000
000
7
LOCATIONS & CONTROLS
8
9
7
10
11
6
12
5
4
3
13
2
14
1
15
16
17
18
25
24
23
22
19
21
8
20
1. ENGINE STARTING BATTERY
2. PUMP OUTLET (DISCHARGE) PORT. Opening for discharge of liquids from the pump. Fittings can be threaded
or bolted to the pump flange.
3. REAR LEVELING JACKS. Used to level the rear of the pump on rough or uneven ground.
4. CHECK VALVE. A valve that permits flow in one direction only. (Required for pump priming.)
5. DRAIN/SUCTION HOSE RELEASE VALVE. (Located on rear skid.) Allows for complete draining of the pump
volute for storage and/or maintenance. This valve can also be opened to relieve pressure on the rear suction
hose to facilitate removal of the hose.
6. PUMP INLET (SUCTION) PORT. Opening for intake of liquids into the pump. Fittings can be threaded or bolted
to the pump flange.
7. REAR HOOD PRIMARY LATCH. See page 12 for hood operating information.
8. FLOODED SUCTION BYPASS VALVE. This valve is used to prevent water from back flowing into the compressor
when there is a flooded suction. The valve should remain open for normal pump operation. (Pictured in open
position.)
9. PUMP VOLUTE (HOUSING). Cast-iron housing for pump mechanical components.
10. ANTI-SHUT LATCH. See page 12 for hood operating information.
11. CENTRAL LIFT EYE. Used for lifting the pump.
12. FRONT HOOD. See page 11 for hood operating information.
13. FRONT HOOD LATCH. See page 11 for hood operating information.
14. FRONT LEVELING JACK. Used to level the pump on rough or uneven ground and to aid in attaching the pump
to a tow vehicle.
15. ENGINE COOLANT DRAIN
16. ENGINE OIL FILL
17. AIR CLEANER ASSEMBLY
18. REAR HOOD. See page 12 for hood operating information.
19. REAR HOOD SECONDARY LATCH. See page 12 for hood operating information.
20. CONTROL PANEL. Controls and indicators for pump operation.
21. MANUAL HOLDER. Storage for operator manuals.
22. ENGINE OIL DRAIN
23. FUEL FILL PORT. Lockable port for filling the fuel tank with clean DIESEL fuel.
24. HAND THROTTLE. Controls pump engine speed.
25. COOLANT OVERFLOW BOTTLE
Note: Use hoses and fittings that are specifically designed and sized for this type of equipment.
9
SPECIFICATIONS
Read this manual carefully before attempting to use this pump. The potential for property damage, personal injury or death
exists if this equipment is misused or installed incorrectly. Read all of the manuals included with this unit. Each manual
details specific information regarding items such as set up, use and service requirements.
MAGNUM MODEL
MTP6500FH
Engine
Make/Brand......................................................................................... John Deere
Model .................................................................................................. PE5030TF270
Type .................................................................................................... Diesel, liquid cooled, 4-stroke
Displacement in3 (L) .......................................................................... 186 (3.1)
Cylinders - qty ..................................................................................... 5
Engine Rated Speed rpm .................................................................. 2800
Engine Power @ Rated Speed - Intermittent hp (kW) ....................... 75.0 (56.2)
Engine Power @ Rated Speed - Continuous hp (kW) ....................... 64.0 (47.8)
Engine Operating Speed rpm ............................................................ 2000
Engine Power @ Operating Speed - Intermittent hp (kW) ................. 67.0 (49.8)
Engine Power @ Operating Speed - Continuous hp (kW) ................ 57.0 (44.4)
Fuel Consumption - 100% load gph (Lph) ........................................ 2.8 (10.6)
Battery Type - Group Number............................................................. 24
Battery Voltage (Quantity per Unit) ..................................................... 12V (1)
Battery Rating ..................................................................................... 720 CCA
Alternator Rating ................................................................................. 70A
Pump
Make/Brand......................................................................................... Pioneer Pump Inc.
Model .................................................................................................. VP66S10L72-EG410
Fitting Size .......................................................................................... 6" NPTF
Impeller Material ................................................................................. Ductile Iron
Impeller Diameter in (mm) ................................................................. 10 (254)
Shaft Material ...................................................................................... Lasalle stressproof (modified AISI 1144 STL)
Volute Material .................................................................................... ASTM A536 Ductile Iron
Wear Plate Material............................................................................. ASTM A536 Ductile Iron
Pump Set (Engine/Pump)
Maximum Diameter of Solids in (mm) ............................................... 3.0 (76.2)
Maximum Pump Output gpm (Lpm) .................................................. 3050 (11546)
Maximum Lift Suction ft (m) ............................................................... 28 (8.5)
Maximum Operating Speed rpm ........................................................ 2200
Total Dynamic Head ft (m) ................................................................. 165 (50)
Sound dB(A) 23 ft @ prime .............................................................. 70
Dimensions (L x W x H)
Skid Mounted in (m) .......................................................................... 95 x 35 x 55 (2.41 x 0.89 x 1.40)
Trailer Mounted in (m) ....................................................................... 150 x 57 x 74 (3.81 x 1.45 x 1.88)
Weights
Dry Weight, Skid Mounted lbs (kg) .................................................... 2733 (1240)
Operating Weight, Skid Mounted lbs (kg) ......................................... 3525 (1599)
Dry Weight, Trailer Mounted lbs (kg) ................................................ 3283 (1489)
Operating Weight, Trailer Mounted lbs (kg) ...................................... 4075 (1848)
Capacities
Fuel Tank Volume gal (L) ................................................................... 110 (416)
Usable Fuel Volume gal (L) ............................................................... 95 (360)
Maximum Run Time hrs .................................................................... 34
Trailer
Number of Axles ................................................................................. 1
Capacity - Axle Rating lbs (kg) .......................................................... 5000 (2268)
Tire Size in ......................................................................................... 15
Brakes................................................................................................. Surge
Hitch - Standard .................................................................................. 2" Ball
Maximum Tire Pressure psi ............................................................... 65
SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.
10
FRONT HOOD OPERATION
WARNING
Stay clear of hood and lift structure when opening and closing pump hoods. Personal
injury may result.
TO OPEN THE FRONT HOOD:
1. With your right hand, grip the handle located on the upper right side of the front panel.
2. With your left hand, pull the hood latch located on the upper corner of the left hood side (see Figure A). Tilt the
hood open until it contacts the bulkhead panel.
CAUTION
Pump hoods are heavy. Use caution when opening or closing.
TO CLOSE THE FRONT HOOD:
1. Make sure skid is free of debris and all personnel are clear of unit.
CAUTION
Do not attempt to close the hood from the sides of the unit. Proceed to the front of the unit
to close the hood. Failure to close the hood correctly could result in personal injury and
equipment damage.
2. While standing at the front of the unit, slowly push the hood forward and allow it to close firmly to ensure the
hood latch is engaged.
3. Verify the hood is securely closed by attempting to open without pulling the hood latch.
11
REAR HOOD OPERATION
WARNING
Stay clear of hood and lift structure when opening and closing pump hoods. Personal
injury may result.
TO OPEN THE REAR HOOD:
1. Open front hood.
2. Verify that the control door is completely closed and secure.
3. Pull lever located under lift structure to release the primary hood latch (see Figure A).
4. Proceed to rear of unit to release the secondary hood latch and tilt the hood open (see Figure B).
A. With your right hand, grip the handle located on the rear of the hood.
B. With your left hand, pull the hood latch located on the upper corner of the left hood side (see Figure C). Tilt
the hood completely open; travel is limited by two metal guide straps.
CAUTION
Pump hoods are heavy. Use caution when opening or closing.
5. Verify the red safety link is engaged and undamaged. This link is located on the left side metal guide strap (see
Figure D).
WARNING
If the red safety link is not properly engaged, unintentional closing of the hood could
result, causing personal injury or equipment damage.
12
REAR HOOD OPERATION
WARNING
Stay clear of hood and lift structure when opening and closing pump hoods. Personal
injury may result.
TO CLOSE THE REAR HOOD:
1. Make sure the skid is free of debris and all personnel are clear of unit.
2. Verify that the control door is completely closed and secure.
3. Release the red safety link located on the left side metal guide strap by rotating the link counterclockwise.
Failure to release the safety link could result in damage to the link or other components.
CAUTION
Do not attempt to close the hood from the sides of the unit. Proceed to the rear of the unit
to close the hood. Failure to close the hood correctly could result in personal injury and
equipment damage.
4. While standing at the rear of the unit, slowly push the hood forward and allow it to close firmly to ensure the hood
latches have engaged.
5. Verify the hood is securely closed by attempting to open without releasing the hood latches.
13
MAIN CONTROL PANEL COMPONENTS
1
12
2
11
3
10
4
VACUUM
9
5
8
6
7
1. DC VOLTAGE GAUGE. Displays DC voltage of the engine starting battery. Typical range is 12-14 volts.
2. FUEL LEVEL GAUGE. Displays the amount of fuel remaining in the fuel tank.
3. ENGINE COOLANT TEMPERATURE GAUGE. Displays engine coolant temperature. Typical range is 180-210°
F.
4. ENGINE OIL PRESSURE GAUGE. Displays engine oil pressure. Typical range is 30-80 psi.
5. VACUUM GAUGE. Used to determine if the pump is achieving prime. After shutdown, this gauge is used to
determine if the pump is holding prime. Typical range is 20-25 in/Hg.
6. CONNECTIONS FOR OPTIONAL FLOAT SWITCHES.
7. EMERGENCY STOP SWITCH. Used to stop engine in case of emergency by interrupting power to the fuel
solenoid.
8. FUEL TRANSFER PUMP SWITCH. Switch for optional fuel transfer pump for extended pump operation.
9. EMERGENCY STOP ACTIVATED LIGHT. Notifies operator that the emergency stop is activated.
10. ENGINE START SWITCH. Used to start and stop the pump engine or to allow for remote starting of the pump
by a dry-contact closure type of switch.
11. CONTROL PANEL LEDS. Indicates various engine operating parameters and faults. These LEDs either flash
or are steady state. See page 15 for more information.
12. ENGINE TACHOMETER/HOUR METER. Displays engine speed in revolutions per minute (rpm) and keeps
track of engine hours for service.
14
CONTROL PANEL LEDS
FLASHING
LOW FUEL /
LOW COOLANT
STEADY
LOW OIL PRESSURE
HIGH TEMPERATURE
OVERCRANK
NO SPEED SIGNAL
ENGINE REST
OVERSPEED
ENGINE RUNNING
PREHEAT
FLASHING LEDS
•
•
•
LOW FUEL / LOW COOLANT: Indicates a low fuel level or low coolant level shutdown (optional).
NO SPEED SIGNAL: Indicates a pump engine shut down due to a loss of signal from the engine’s magnetic
pickup. Refer to the TROUBLESHOOTING section for possible causes.
ENGINE REST: Indicates the engine has paused between starting attempts.
STEADY STATE LEDS
•
•
•
•
•
•
LOW OIL PRESSURE: Indicates a pump engine shut down due to low engine oil pressure. Refer to the
TROUBLESHOOTING section for possible causes.
HIGH TEMPERATURE: Indicates a pump engine shut down due to the coolant temperature exceeding 235°
F. Refer to the TROUBLESHOOTING section for possible causes.
OVERCRANK: Indicates the pump engine failed to start after three attempts. Refer to the TROUBLESHOOTING section for possible causes.
OVERSPEED: Indicates shutdown due to the pump engine running too fast. Refer to the TROUBLESHOOTING section for possible causes.
ENGINE RUNNING: Indicates proper operation of the pump engine.
PREHEAT: Indicates operation of the engine’s glow plugs during the engine starting procedure.
15
PRE-USE CHECKPOINTS
Before using the pump, be sure to check the following:
•
•
•
•
Place the pump as close as possible to the liquid being pumped, keeping the number of hose sections and
couplings to a minimum. The pump should be the highest point between the intake and outlet section of the
hoses.
Make sure the ground is firm and as level as possible.
Check the pump discharge area; make sure it will not erode the material under the pump or damage any
nearby structures.
Make sure all hose couplings are of the same size and type.
WARNING
The pump is designed to handle water and/or other liquids containing some slurries
and other entrapped solids up to 3.0 inches (7.6 cm) in diameter. It MUST NOT be
used to pump volatile, corrosive or flammable materials that may damage the pump,
cause pump failure or result in explosion!
PUMP SET UP
1. Disconnect the pump from the tow vehicle by turning the tongue jack clockwise to raise the tongue from the
hitch. Disconnect all safety chains, surge brake cables and the trailer wiring harness.
2. Lower rear leveling jacks from the travel position. Turn the jack handles clockwise until the leveling feet are in
firm contact with the ground. Adjust the front and rear jacks until the pump is as level as possible.
3. If necessary, open the rear hood and attach fittings to both the intake and outlet openings of the pump, making
sure they match the fittings on the hoses. Make sure a gasket/seal is in place between the pump volute and the
flange on the fitting being attached. Tighten all hardware completely to ensure an airtight seal. Threaded fittings
require the use of pipe thread sealant/lubricant.
SE
AL
SE
AL
4. Attach a rigid fill hose or pipe to the intake (suction) side of the pump. Make sure the seals are present in the
fitting on the pump before attaching fittings. Note: Lubricate the seals to ensure an airtight seal.
5. Attach a rigid intake screen or strainer to the end of the fill hose before placing it in the liquid. This will prevent
large items or excessive trash from entering the pump housing. The screen must have enough openings to equal
4 times the area of the intake hose (6” x 3.14 = 18.84 sq. in x 4 = 75.36 sq. in.).
6. Attach a flexible hose to the outlet (discharge) side of the pump. Make sure the o-ring seal is present in the fitting
on the pump before attaching the fitting. Note: Lubricate the seal to ensure an airtight seal.
7. Check the intake and outlet hoses for sharp bends or kinks that may restrict pump flow before proceeding. The
intake hose should slope upwards toward the pump to avoid development of air pockets in the hose which may
lead to pump cavitation. Keep the hoses as straight as possible.
The pump is now ready for use.
16
STARTING THE PUMP
Before starting the pump, be sure to check the following:
•
•
•
•
Make sure all hose couplings, covers and plugs are tight.
Check the oil level in the mechanical seal oil reservoir bottle. Do not allow the bottle to run dry.
Check the engine oil level, coolant level and fuel level.
Make sure the engine starting battery is connected.
1. Make sure the Emergency Stop switch is pulled out (deactivated).
2. Push the Engine Start Switch up to the MANUAL START position. The PREHEAT LED on the control panel will
light up to indicate activation of the engine glow plugs. Once sufficient time has passed, the engine should crank,
start and run, slowly building up speed.
3. Allow the engine to run until it reaches a constant speed. Once it is running smoothly, the engine speed can be
adjusted by the throttle, located above the fuel fill port.
To adjust the engine speed:
A. Loosen the locking ring on the throttle, located next to the mounting bracket, by turning counterclockwise.
B. Push and hold the center button on the throttle:
○ PULL the throttle out to INCREASE engine speed.
○ PUSH the throttle in to DECREASE engine speed.
C. Fine engine speed adjustment can be made by turning the throttle clockwise or counterclockwise.
D. Once the desired engine speed has been attained, lock the throttle by turning the locking ring clockwise.
PU
SH
PU
LL
4. The pump should prime and begin to discharge liquid within minutes. A high suction lift or low engine speed will
require a longer time to prime and pump.
5. Use the engine throttle to adjust the pump flow. Several factors can influence pump output:
• The temperature, viscosity amount of entrapped solids in the liquid being moved.
• The length, diameter and number of bends of the intake and outlet hoses.
• The total suction height (lift) of the pump.
• The altitude above sea level where the pump is operating.
WARNING
Never adjust the pump flow by attaching a valve to the intake or outlet side of the
pump. Restricting the flow in this way can cause the pump to overheat, creating
extreme pressure inside the pump volute. Explosion of the pump volute and serious
personal injury may result!
6. As the pump operates, avoid running the intake side of the pump dry. Air from the intake side of the pump may
cause cavitation, causing damage to the pump impeller. The intake hose must be kept 4-5 times the hose diameter
(4-5 x 6” = 24-30”) below the surface of the liquid being pumped.
17
7. Use the table below for approximate flow rates for the 6” pump.
6 Inch
SUCTION SPECIFICATIONS
B
C
A
A = Suction Lift: The distance between the centerline of
the pump impeller and the surface of the liquid being pumped.
B = Vertical Discharge Head: Vertical distance from the centerline of
the pump inlet to the centerline of the highest point of discharge.
C = Total Dynamic Head (TDH): Suction lift plus vertical discharge
plus friction loss.
Note: To calculate PSI, divide TDH in feet by 2.31.
Example: TDH (35 ft.) = 15.15 PSI
2.31
18
STOPPING THE PUMP
1. Reduce the engine speed by adjusting the engine throttle.
2. Allow the engine to idle briefly before switching the engine start switch to the center (OFF) position.
Do not use the Emergency Stop switch unless absolutely necessary. Stopping the pump
suddenly may cause shock waves to be transmitted back to the pump volute, causing pump
damage. To activate the emergency stop, push the stop switch in. To deactivate the switch,
pull the switch out.
3. The pump is adequately prepared for outside storage. See the pump Operation and Maintenance Manual for
additional suggestions for long-term storage.
In freezing temperatures, drain the pump volute case of pumpage when the unit is idle to
avoid freezing and possible equipment damage.
AUTOMATIC SHUTDOWN
The pump is equipped with a low oil pressure and a high temperature automatic shutdown system. This system will
automatically shut off the fuel supply to stop the engine if oil pressure drops too low or the engine exceeds normal
operating temperature. Return the engine start switch to the “OFF” position to reset the controller; restart the pump
engine after you have determined the cause of the shutdown. Refer to the ENGINE FAULT SHUTDOWN TROUBLESHOOTING section for more information.
REMOTE/AUTO STARTING
The pump can be configured to start automatically by the addition of dry-contact closure float level switches. These
connections are found on the control panel next to the emergency stop button. Both float switches must be connected
for automatic starting to occur. Contact Magnum Products’ Technical Service Department at 1-800-926-9768 or 1920-361-4442 for more information.
ENGINE AND PUMP MAINTENANCE
Poorly maintained equipment can become a safety hazard! In order for the equipment to operate safely and properly
over a long period of time, periodic maintenance and occasional repairs are necessary. NEVER perform even routine
service (oil/filter changes, cleaning, etc.) unless the engine start switch is turned to off “O” and the negative (-) cable
on battery is disconnected. Attach a “DO NOT START” sign to the control panel. This will notify everyone that the
unit is being serviced and will reduce the chance of someone inadvertently trying to start the unit.
Never wash the unit with a high pressure hose or with any kind of power washer. Never wash the engine block or
fuel tank with a power washer or steam cleaner. Water may collect in the pump control panel or other electrical parts,
causing damage.
ENGINE BREAK-IN REQUIREMENTS
Note: During the first 20 hours of operation, avoid long periods of low engine speed or sustained maximum engine
speed. The engine is supplied with engine break-in oil from the factory. Extra care during the first 100 hours of engine
operation will result in better performance and longer engine life. Note: DO NOT exceed 100 hours of operation
with the break-in oil. Operate the engine at high engine speeds (60-90% of maximum) as much as possible. If the
engine has spent significant time at idle, constant speeds and/or light load or if makeup oil is required, a longer breakin period may be needed. Consult the engine OPERATION AND MAINTENANCE MANUAL for a full description of
necessary procedures on the addition of break-in oil and extension of the break-in period.
19
PUMP BEARING FRAME LUBRICATION
The lubrication of the ball bearings depends on speed, load, ambient temperature, contamination, moisture,
intermittent or continuous service and other factors. These re-greasing recommendations are general and are to be
used with good judgement and consideration of the pump service. The following table contains suggested lubrication
intervals:
2200 RPM
1800 RPM
1200 RPM
2,500 Hours
3,500 Hours
5,000 Hours
To lubricate the ball bearings, remove the plastic covers from the zerk fittings. Ensure that the zerk fitting and the
end of the grease gun are clean. Use only a hand-operated grease gun with ball bearing grease. Use one of the
following, or equivalent; Texaco Starplex Moly 2, Mobile MobiLux No. EP2, Shell Alvania EP2, Chevron SRI.
MECHANICAL SEAL LUBRICATION
The mechanical seal oil reservoir supplies lubrication and cooling to the outboard side of the mechanical seal without
any liquid in the pump. Monitor the oil level in the oil fill bottle, add oil as needed. During normal operation the oil
should be changed every three months, or more frequently if contamination or discoloration is detected. The external
oil reservoir (bottle) is filled via a plug on the top of the bottle. There is a petcock located on the opposite side of the
run-dry gland from the oil inlet line. During initial filling, this petcock should be opened to allow the air to vent from
the gland.
Use turbine oil with an ISO rating of 32 or lower. If you have unusual pumping conditions contact Pioneer Pump, Inc.
Oil used in the reservoir (bottle) should be ISO VG 32 Turbine Oil or Automatic transmission oil, equivalent to one
of the following manufacturer’s products: Chevron Turbine oil GST 32, Mobile DTE 797, Shell Turbo T oil 32.
MECHANICAL SEAL
OIL RESERVOIR
BALL BEARING
GREASE ZERK
20
DAILY WALK AROUND INSPECTION
Look for conditions that could hinder performance or safety, such as (but not limited to) oil/coolant/fuel leakage,
blocked vents, loose/missing hardware and electrical connections
Visually inspect the fan belt for cracks, fraying, stretching and that the belt is properly seated in pulley grooves.
Replace the belt according to the manufacturer’s recommendations.
Note: At the 500 hour/12 month service interval, it is recommended that the belt be removed and checked for wear.
While the belt is removed, inspect pulleys and bearings. Rotate and feel for hard turning or unusual sounds. If pulleys
or bearings need replacement contact John Deere.
Note: Failure to perform a daily inspection may result in serious damage to the prime mover.
BELT TENSION
John Deere engines use two types of belt tensioners: manual and automatic. Adjust the belt using the manual
tensioner according to the manufacturer’s specifications. The automatic tensioner cannot be adjusted or repaired
and is designed to maintain proper tension over the belt’s life. Units with the automatic belt tensioner must be inspected
according to the manufacturer’s specifications.
MAINTENANCE SCHEDULE
The periodic maintenance schedule below lists basic maintenance intervals for the pump and engine. For detailed
maintenance procedures refer to the Engine Operator’s Manual and the Pump Operation & Maintenance Manual.
Copies of these manuals were supplied with the unit when it was shipped from the factory. For additional or replacement
copies of these manuals, contact an authorized dealer in your area.
Maintenance Action
Daily
Check Engine Oil Level

Check Engine Coolant Level

Check Fuel Level

Check Mechanical Seal Oil Level
*
Check for Fuel Leaks

Check for Coolant Leaks

Check Fan Belt Tension

Check Tire Inflation

Check Flange Fitting Hardware

100
Hours
Check Fan Belt Condition

Clean Fuel Filter

Check Condition of Wear Plate

250
Hours
Change Mechanical Seal Oil
*
Change Engine Oil and Filter
**
Check Condition of Volute Seals

Check Exhaust System Components

Replace Fuel Filter Element

Clean Air Filter Element, Replace if Necessary
500
Hours
2000
Hours
2500
Hours

21
Maintenance Action
Daily
100
Hours
250
Hours
500
Hours
Service Battery

Flush Cooling System

Clean Crankcase Vent Tube

Check Compressor Mounting Hardware

Replace Fan Belt

2000
Hours
Replace Cooling System Hoses

Pressure Test Cooling System

Check Engine Valve Clearance

Check Flex Coupling Condition

Check Pump to Engine Hardware

2500
Hours
Lubricate Pump Bearings
***
*
See “MECHANICAL SEAL LUBRICATION” on page 20 for details.
** Change the engine oil and oil filter after the initial 100 hours of operation, then every 250 hours thereafter.
*** See table on page 20 for bearing lubrication details.
TOWING THE TRAILER
1. Use the jack to raise or lower the trailer onto the hitch of the towing vehicle. Lock the hitch coupling and attach
the safety chains or cables to the vehicle. Release the jack locking pin and rotate the jack into the travel position.
Make sure the locking pin snaps into place.
2. Connect any trailer wiring to the tow vehicle. Check for proper operation of the stop and signal lights.
3. Check for proper inflation of the trailer tires.
4. Check the wheel lugs. Tighten or replace any that are loose or missing. If a tire
has been removed for axle service or replacement, tighten the lugs in the order
shown to the following specifications:
A. Start all lug nuts by hand.
B. First pass tighten to 20-25 Ft-Lbs (27-33 Nm).
C. Second pass tighten to 50-60 Ft-Lbs (67-81 Nm).
D. Third pass tighten to 90-120 Ft-Lbs (122-162 Nm).
1
3
6
4
5
2
After the first road use, retorque the lug nuts in sequence.
5. Maximum recommended speed for highway towing is 45 mph. Recommended
off-road towing speed is not to exceed 10 mph or less depending on terrain.
TRAILER WHEEL BEARINGS
The trailer is equipped with a grease zerk fitting to allow lubrication of the wheel bearings without the need to
disassemble the axle hub. To lubricate the axle bearings, remove the small rubber plug on the grease cap, attach a
standard grease gun fitting to the grease zerk fitting and pump grease into the fitting until new grease is visible around
the nozzle of the grease gun. Use only a high quality grease made specifically for lubrication of wheel bearings. Wipe
any excess grease from the hub with a clean cloth and replace the rubber plug when finished. The minimum
recommended lubrication is every 12 months or 12,000 miles; more frequent lubrication may be required under
extremely dusty or damp operating conditions.
22
LIFTING THE PUMP
Only lift the pump with equipment that is in good condition and that is rated to support the weight of the pump. See
the specifications on page 10 for approximate weights. A central lifting eye is located on the top of the pump. The
eye is connected to a central lifting frame. Attach a sling or hook directly to the lifting eye. Always remain aware of
others around you when moving or lifting the pump. Suction and discharge hoses and piping must be removed from
the pump before lifting.
CENTRAL
LIFT EYE
ww
w
m
-p
-llc
co
m
23
PUMP TROUBLESHOOTING
PUMP TROUBLESHOOTING
SYMPTOM
POSSIBLE CAUSE
SOLUTION
Pump will not prime
Back pressure condition in
discharge hose
Drain fluid from discharge line
Air leak in suction hose or fitting
Tighten all connections, lubricate fitting seals
Intake insufficiently submerged
Lower intake hose
Air leak in intake hose
Air leak at pump housing
Low pump output
Air trapped in intake hose
Relocate and/or straighten intake hose
Engine speed too low
Increase engine speed
Intake hose collapsed
Replace intake hose with a
more rigid one
Suction lift too high
Relocate pump
Excess air in liquid
Allow liquid to settle
Total head too high
Reduce inlet and outlet hose length
Impeller obstructed
Remove pump suction flange and check for
obstructions
Worn pump components
Check wear plate and impeller for wear
or damage
Intake insufficiently submerged
Air leak in intake hose
Air leak at pump housing
Vibration and/or noise
when pump is operating
Change engine speed
Intake hose collapsed
Replace intake hose with a
more rigid one
Suction lift too high
Relocate pump
Excess air in liquid
Allow liquid to settle
Total head too high
Reduce inlet and outlet hose length
Impeller obstructed
Remove pump suction flange and check for
obstructions.
Improper or low lubrication
at mechanical pump seal
Check wear plate and impeller for wear
or damage
Stop pump, inspect oil level at
mechanical seal oil fill bottle
Pump cavitation
Reduce engine speed, lower intake hose
Worn pump bearings
Repair pump
Impeller obstructed
Remove pump suction flange and
check for obstructions
Worn pump components
Improper or low lubrication
at mechanical pump seal
Worn pump bearings
24
Lower intake hose
Inspect intake hoses and couplings for damage
or missing components and seals
Inspect gaskets, seals and o-rings
at pump intake flange.
Engine speed incorrect
Worn pump components
Pump is overheating
Inspect intake hoses and couplings for damage
or missing components and seals
Inspect gaskets, seals and o-rings
at pump intake flange, cleanout
cover and priming port
Check wear plate and impeller for wear
or damage
Stop pump, inspect oil level at
mechanical seal sight glass
Repair pump
ENGINE FAULT SHUTDOWN TROUBLESHOOTING
switch
switch
switch
switch
25
TRAILER LIGHTS WIRING DIAGRAM
26
DC WIRING DIAGRAM
GRY
L
BLK
S
REMOTE START
MANUAL START
FUEL
PREHEAT
LED OUTPUTS
OVERCRANK
TEMP SWITCH
OVERSPEED
OIL SWITCH
ENGINE RUN
FAILURE
LED TEST
BLU
L
S
GND
19 20
WARMUP
COMMON GND
WATER
BLK
LOW OIL
HIGH TEMP
AUX SWITCH
BLK
GND
REMOTE START
VIO
12
AUTO MODE
CRANK
1 2 3 4
11
17 18
YEL/WHT
10
16
GRY/BLK
9
BAT
WHT/VIO
BLK
8
14 15
RED
7
13
RED
6
RED
FUEL
GND
5
RED
RED
BAT
RED
#3
#2
GRD
BAT
BAT
OIL
RED
-
+
L
S
GND
VIO
GRY
N/C
85
86
L
L
Engine Controller
S
GND
SPEED SIGNAL
YELL
BLK
#1
N/O
87A
SIG
VIO
BLU
YEL
-
+
87
COM
N/C
85
86
-
+
DC VOLTS
30
GRN/YEL
N/O
87A
COM
N/C
85
86
87
GRN/YEL
ORN
N/O
87A
COM
GRY
30
RD/WHT
87
RED
30
YEL
ORN
RED
BLK
TACH
BAT
BLU
BLK
WHT/BLU
RED
BLK
YEL
STARTER
SOLINOID
10
PINK
ORN
PINK
9
BLK
8
RED
FUSE
25 AMP
R
4
1
5
2
6
3
ESTOP LED
RED
RED
5
RED
6
7
RED
C+
YEL
10 AMP
RD/WHT
ESTOP
NC1 NC2
ESTOP
3
WHT
GLOW
SOLINOID
RED
4
BLK
RED
2
YEL
NO4
WHT
1
NO3
C+
RED
BLK
BLK
YEL
BLK
RD/WHT
ORN
GRY
BLK
YEL
VIO
WHT/BLU
BLU
BLK
WHT/VIO
BLK
YEL/WHT
GTB
12/B
9
11
8
10
7
6
5
4
1
3
2/B
GRY/BLK
BLK
BLK
BLK
YEL
ORN
ALTERNATOR
13
10
7
4
1
14
11
8
5
2
15
12
9
6
3
15
12
9
6
3
14
11
8
5
2
13
10
7
4
1
GLOW PLUG
MOTOR
STARTER
BLK
WHT
YEL
WHT/VIO
FUEL SENSOR
WATER SENSOR
CRANK SENSOR
BLK
OIL SENSOR
WHT
RED
BLK
RED
B+
BATTERY 12V
RED
RED
LOW COOLANT
OIL SWITCH
FUEL
SOLENOID
BLK
TEMP SWITCH
WHT/BLU
VIO
BLK
RED
RED
B+
27
REV: E
PART NO: 41561
01.28.11
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