Magnum MTP6000S3 Operating Manual Download

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POWER PRODUCTS LLC

SELF-PRIME DIESEL TRASH PUMP

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MTP6000S3

OPERATING MANUAL

Summary of Contents for MTP6000S3

Page 1: ...Parts manuals available online www m p llc com POWER PRODUCTS LLC SELF PRIME DIESEL TRASH PUMP www m p llc com www m p llc com MTP6000S3 OPERATING MANUAL ...

Page 2: ...d professional perform all electrical wiring and testing functions Any wiring should be in compliance with the National Electrical Code NEC state and local codes and Occupational Safety and Health Association OSHA guidelines MAGNUM POWER 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 p...

Page 3: ...TLING MENU 24 TELEMETRY MENU 25 DB VIEWER 26 PREFERRED SCREEN STORE 26 POP UP MESSAGES AND ALERTS 26 ADJUSTING LIGHTING AND CONTRAST 27 DATA PARAMETERS MONITORED 27 ENGINE BREAK IN REQUIREMENTS 29 PUMP PRE USE CHECKPOINTS 29 PUMP SET UP 30 STARTING THE PUMP 32 SUCTION SPECIFICATIONS 34 LIQUID TEMPERATURE AND OVERHEATING 34 PUMP VACUUM CHECK 34 BEARING TEMPERATURE CHECK 34 STOPPING THE PUMP 35 EMER...

Page 4: ... STORAGE 44 PRODUCT FLUSH OPTION 45 PUMP TROUBLESHOOTING 46 ENGINE FAULT SHUTDOWN TROUBLESHOOTING 47 CONTROL SYSTEM TROUBLESHOOTING 48 DC WIRING DIAGRAM 49 TRAILER LIGHTS WIRING DIAGRAM 50 SERVICE LOG 51 ...

Page 5: ...5 This Page Intentionally Left Blank ...

Page 6: ...rstand 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 andcontrols Inexperiencedoperatorsshould...

Page 7: ... 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 Notic...

Page 8: ...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 Check the temperature before opening any pump covers plates or plugs Allow the pump to cool if overheated Before servicing the pump end close the suction and discharge valves Vent the pump slowly and cautiously Drain th...

Page 9: ... Magnum Power 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 UNIT SERIAL NUMBER LOCATIONS Refer to the locations illustrated to...

Page 10: ... manual before operating unit Remove negative battery cable before performing any service on unit Moving parts can crush and cut keep body parts clear of this area Use clean diesel fuel only Hearing protection required while operating unit Anchor tie down point Lift here only Asphyxiation hazard operate in well ventilated area Hazardous voltage Disconnect battery before servicing Rotating impeller...

Page 11: ... 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 1720 6510 Maximum Lift Suction ft m 28 8 5 Maximum Operating Speed rpm 2300 Total Dynamic Head ft m 165 50 3 Sound dB a 23 ft prime 80 Dimensions Skid Mounted in m 82 x 35 x 60 2 08 x 0 89 x 1 52 Trailer Mounted in m 138 x 57 x 78 3 51 x 1 45...

Page 12: ...12 COMPONENT LOCATIONS 3 2 1 4 7 6 5 8 9 10 11 12 13 14 15 6 16 17 ...

Page 13: ...he pump Fittings can be threaded or bolted to the pump flange 10 PUMP VOLUTE HOUSING Cast iron housing for the pump mechanical components 11 PUMP INLET SUCTION PORT Opening for intake of liquids into the pump Fittings can be threaded or bolted to the pump flange 12 PUMP CLEANOUT COVER Provides access to pump internals for cleaning and or maintenance 13 PRESSURE RELIEF VALVE Safety device that will...

Page 14: ... access a context dependent button bar when any button from 1 to 4 is pressed The graphical menu structure uses easily understood icons to indicate the button s current function After five seconds of inactivity the button bar disappears Note Most problems with electronically controlled engines can be pinpointed via ECU diagnostic messages Use the display or ECU diagnostic tool to view fault codes ...

Page 15: ...atmospheric and engine conditions After waiting for the Preheat screen to extinguish the engine is cranked by turning and holding the key switch in the START position until the engine starts Note The ECU will not preheat unless conditions warrant If necessary starting the engine may be attempted by turning the key to the START position without waiting for preheat to expire The key switch is spring...

Page 16: ... specific view of CANbus data Gauges on the current page can be changed via Adjust mode accessed by pressing button 5 when the button bar is visible Gauges can be changed on any of the four pages by selecting the page to be changed and then entering Adjust mode Note Quad Adjust must me enabled to access the Adjust mode In Adjust mode a new button bar is displayed identifying the button functions B...

Page 17: ...g button 3 while in the Single Analog Gauge mode while the menu bar is visible The currently displayed gauge is stored when power is removed refer to Preferred Screen Store Note Gauge selections are limited to the data currently being received Refer to Data Parameters Monitored for a complete list of available parameters ACTIVE ALARMS A flashing pop up window is overlaid on the current screen when...

Page 18: ...parameters that typically need to be restricted such as Maximum RPM are accessible only through the CANplus Configurator The CANplus Configurator is a Windows PC program and a hardware adapter that allows total access to the parameters of the panel For more information about the CANplus Configurator please contact Magnum Power Products LLC CONFIGURATION MENU This Configuration menu allows the user...

Page 19: ...ch German Spanish Italian Dutch and Portuguese The currently selected value is indicated by the Check Mark Button 4 selects the highlighted value BUTTON BEEP The soft buttons emit an audible beep when this item is On Button beep is disabled by setting this item to Off The audible beep still sounds when an alarm occurs Button 4 cycles between On and Off GAUGES MENU This menu allows the user to conf...

Page 20: ...while button 2 increases the service interval time in 10 hour increments Holding button 3 for approximately three seconds resets Next Service In to the current service interval The service timer descriptions can be changed using the CANplus Configurator Note It is not possible to set the service timers if engine hours are not being received by the display SYSTEM MENU The System menu allows the use...

Page 21: ...ation transmitted by the ECU Setting US Metric Language English Button Beep On Service Timers Off Display Mode Analog Gauges Gauge Pages Defaults Quad Adjust On Demo Mode 0 Off Engine Source 0 Display CAN Address 40 Alarm Filter Glb SPN Version 1 Speed Source Auto PIN Entry Off PIN 1111 Max Gauge RPM 2500 Max Gauge Speed 40 MPH 60 km h Speed Units MPH km h Distance Units Miles km Pressure Units PS...

Page 22: ... Button 2 selects the next page of engine configuration while button 1 selects the previous page J1939 SETTINGS This screen allows adjustments specific to the J1939 data link ENGINE SOURCE Selects which source the display listens to for gauge data Every device on a J1939 network has a unique address in the range 0 254 to which the display can choose to listen The display listens to a single data s...

Page 23: ... speed data the display can decode The settings for this parameter are Auto NMEA Wheel Nav and Off Auto prioritizes the sources highest to lowest NMEA Wheel PGN 65265 Nav PGN 65272 The selection can be forced to one of the available sources by selecting it explicitly Selecting Off stops the display listening to any source of speed data PIN SETTINGS By default PIN security is disabled The user is p...

Page 24: ...rial number used to program the controller VERS Software version number PRODUCT Controller model name RUN TIME Hours the unit has been run THROTTLING MENU The Throttling menu allows the user to configure throttle control This allows changing the PIN The user is prompted for the current PIN The user is prompted for the new PIN The new PIN must be confirmed before the PIN is changed If the new PINs ...

Page 25: ... changing the panel minimum requested RPM and maximum requested RPM INTERMEDIATE RPM Selects the RPM the control system will request for intermediate speed Note Intermediate RPM is the middle setting of optional three state throttle switches RUN RPM Selects the RPM the control system will request for run speed Note Run RPM is the high speed setting of the optional two state or three state throttle...

Page 26: ...s diagnostic tool allows viewing data not normally displayed The list can be scrolled using buttons 1 and 2 and closed by pressing button 5 Note The Database Viewer is always in English regardless of language selected PREFERRED SCREEN STORE The display automatically stores the current screen as the preferred screen after a delay of approximately 15 seconds The display will use the last stored scre...

Page 27: ...nation Contrast is adjusted in the same manner using buttons 3 and 4 Note The display adjusts the contrast with ambient temperature Manual contrast adjustments are only necessary with extreme climate change The menu is exited by pressing button 5 The lighting andcontrast settings are retained after the unit is powered off Note If the contrast has been adjusted poorly the factory setting is restore...

Page 28: ...ail 2 Pressure Engine Coolant Pressure Engine Oil Pressure Injector Control Pressure Temperature ºC ºF Engine Coolant Temperature Engine Intercooler Temperature Engine Oil Temperature Turbo Oil Temperature Intake Manifold Temperature Air Inlet Temperature Exhaust Temperature Auxiliary Temperature 1 Engine ECU Temperature Exhaust Gas Port 1 Temperature Exhaust Gas Port 2 Temperature Turbo Inlet Tem...

Page 29: ...ntervals refer to Basic Maintenance Schedule John Deere Engine on page 37 PUMP 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 suction hoses Make sure the ground is fi...

Page 30: ...require the use of pipe thread sealant 4 Attach a rigid hose to the intake suction side of the pump To prevent cavitation the suction hose piping should be at least as large as the pump flange never smaller The pump should be at the highest point of the hose piping All suction piping and fittings should be checked for any foreign material rocks bolts wire etc and also any sharp burrs that could di...

Page 31: ...piping fill plug and other fittings are securely installed Failure to do so could cause liquid pumped to be forced out under pressure causing injury to personnel 10 The pump is self priming but should never be operated unless there is liquid in the pump casing The pump casing needs to be half filled with liquid in order to prime Remove the cover from the top of the pump volute and fill the pump ca...

Page 32: ...ngine by turning and holding the key switch in the START position until the engine starts Refer to page 15 for details 3 Allow the engine to run until it reaches a constant speed Once it is running smoothly the engine speed can be adjusted with the Speed Control switch located above the Engine Start switch on the control panel A Press and release the Rabbit icon to increase the speed B Press and h...

Page 33: ... the intake side of the pump may cause cavitation causing damage to the pump impeller The intake hose must be kept four to five times the hose diameter 4 5 x 6 24 30 61 76 cm below the surface of the liquid being pumped 7 Use the table below for approximate flow rates for the 6 pump 1680 1580 1480 1380 1280 1180 1080 980 880 1780 FLOWRATE U S GALLONS PER MINUTE FLOWRATE CUBIC METERS PER HOUR TOTAL...

Page 34: ...erhaul or any time the pump casing overheats and activates the valve PUMP VACUUM CHECK With the pump inoperative install a vacuum gauge in the system Make sure the pump is at least half filled with liquid Block the suction line and start the pump At operating speed the pump should pull a vacuum of 20 in of mercury 67728 Pa or more If it does not check for air leaks at the suction piping gaskets BE...

Page 35: ... 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 Engine Fault Shutdown Troubleshooting on page 47 for more...

Page 36: ...ecifications on page 11 for approximate weights Always remain aware of the position of other people and objects around you as you move the unit A central lift point is located on the top of the unit Attach any slings chains or hooks directly to the lift point Use the forklift pockets with care Approach the unit as perpendicular as possible to avoid any damage to the unit Make sure any obstructions...

Page 37: ...s a guide for regular maintenance intervals For additional or replacement copies of the engine operator s manual contact an authorized dealer in your area Item Daily 250 Hrs 500 Hrs 12 Months 2000 Hrs 24 Months As Required Check Oil Level Check Coolant Level Check Fuel Level Check Tire Pressure Check All Electrical Connections Inspect Radiator Fins For Debris Clean As Required Check Fuel Filter Ch...

Page 38: ...conditions Failure of operating personnel to be familiar with all aspects of pumpoperationoutlinedinthismanualcouldcontributetoequipmentdamage bodily injury or possible death Before servicing 1 Verify that the Engine Start switch is turned to OFF and the negative cable on the battery is disconnected 2 If the pump or components are hot allow adequate cooling prior to servicing the unit 3 Close the ...

Page 39: ...because of its rugged construction However all centrifugal pumps contain wear parts that will gradually deteriorate affecting pump performance This pump does contain wear parts and these parts should be replaced as required to maintain optimum performance General maintenance can be performed without removing the pump from the engine The following instructions assume a complete disassembly of the p...

Page 40: ...rew the impeller from the shaft The impeller was installed at the factory using Loctite and so may be fairly difficult to unscrew A propane torch can be used to ease loosening the screw if necessary Use the impeller removal tool to fix the shaft from rotating and use a metal bar or piece of wood to rotate the impeller counter clockwise until it is free of the shaft It may be necessary to pound the...

Page 41: ... Plug Illustration on page 40 and drain oil Clean plug and reinstall in housing Remove fasteners and slide the bearing cap SAE bracket and grease seal off the shaft Press the grease seal from the bearing cap SAE bracket Place a block of wood against the impeller end of the shaft and gently tap the shaft and bearings out of the housing BEARING REMOVAL Remove the shaft snap ring This will require th...

Page 42: ...n on the old seal can cause premature failure if reused Thoroughly clean the shaft where the mechanical seal will be installed and the seat of the seal housing Place the sleeve O ring over the shaft past the threads and up against the shaft shoulder Lubricate the stationary seat bore and stationary seat O ring with P 80 30 wt motor oil or liquid dish detergent and a little water DO NOT USE GREASE ...

Page 43: ...the impeller is making contact with the wear plate then re measure the same gap until the above increase in clearance is achieved at each corner of the bearing housing Rotate shaft making sure there isn t any impeller wear plate contact or rubbing Tighten the jack screws at each corner of the bearing housing not too tight then tighten the jack screw lock nuts to maintain setting position Rotate sh...

Page 44: ...ne oil and fill through the air vent hole at the top right of the bearing frame Under normal use drain and refill bearing housing at least once every 12 months CAUTION Over filling with oil can result in premature failure of bearings STORAGE The unit is adequately prepared for outside storage prior to shipment Use the following list of additional suggestions for extended storage 1 Disconnect the b...

Page 45: ...e pressure Water will flow through the seal housing into the pumpage to keep it from entering the seal housing TORQUE VALUES Note The above values are general in nature If a grade 2 or 5 capscrew is threaded into stainless steel use the lower value i e 304 stainless SIZE UNC MATERIAL 304 SS GRADE 5 BOLTS GRADE 8 BOLTS 5 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 1 1 1 4 3 0 ft lb 7 0 ft lb 13 ft lb 20 ft lb...

Page 46: ... Suction pressure to vapor pressure below minimum 10 Suction lift too high 11 Excess vapor in pumpage 12 Specific gravity of pumpage housing different than design 13 Viscosityofpumpagedifferent than design 14 Operation at below rated capacity 15 Cavitation 16 Electrolysis 17 Impeller obstructed 18 Wrong rotation direction 19 Low speed 20 Air leak into suction line 21 Air leak through mechanical se...

Page 47: ...nual Overcrank shutdown Pump engine will not start Consult engine operating manual Overspeed shutdown Pump cavitation Reduce engine speed lower intake hose Air trapped in intake hose Relocate and or straighten intake hose Intake insufficiently submerged Lower intake hose Air leak in intake hose Inspect intake hoses and couplings for damage or missing components and seals Air leak at pump housing I...

Page 48: ...ulty connection to battery Correct battery connections Faulty control system Repair or replace control system Display does not display data Display lost power Turn on key verify display plugged into harness Engine Source address incorrect Change Engine Address in Config uration Display Address incorrect Change Display Address to 40 default Display configuration problem Reset display using Restore ...

Page 49: ...M N P A ALT ECM GLOW K 1 G 3 G 4 A 1 K 2 B 1 L 1 L 4 M 1 M 4 L 2 L 3 M 2 B 2 DIAGNOSTIC CONNECTOR GLOW PLUG RELAY BLK WHT C15 BLK WHT C02 LOW COOLANT RED BLK VIO YEL CLR BLK WHT GRY BLK ORG BLK WHT BLU BLK YEL RED BLK RED RED RED BLU RED WHT 120 RESISTOR JD HARNESS JD HARNESS BLK VIO YEL BLK WHT BLK WHT BLK WHT CP600 CONTROLLER FLOAT SWITCHES GY BK BN BK WT BK BK WT HIGH LOW SPLICE SPLICE FUSABLE ...

Page 50: ...AGRAM 90228_ORG_05 09 12 BLK WHT BLK WHT WHT BRN YEL GRN TRAILER PLUG AMBER MARKER LAMP AMBER MARKER LAMP STOP TURN SIGNAL LAMP RIGHT STOP TURN SIGNAL LAMP LEFT PLATE LAMP WHT WHT GRN BRN YEL BRN TO MOUNTING STUD TO MOUNTING STUD ...

Page 51: ..._______________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ ____________________...

Page 52: ...REV C PART NO 49519 10 11 13 CANplus and CANplus logo are registered trademarks of LOFA Industries Inc CP600 is a trademark of LOFA Industries Inc ...

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