mg-30 user guide 2.2 - phoenix geophysics · 2010. 7. 20. · 2 chapter 1 about this guide 2 about...

MG-30 Motor GeneratorUser Guide

Version 2.2 December 2004

PHOENIX GEOPHYSICS

Printed in Canada on water resistant Xerox® Laser Never-Tear paper.

This User Guide was created in Adobe FrameMaker 7.0, using Verdana, Tahoma, and Lucida Bright fonts. Writing and Production: Stuart Rogers.

Copyright 2004 Phoenix Geophysics Limited.

All rights reserved. No part of this Guide may be reproduced or transmitted in any form or by any means electronic or mechanical, including photocopying, recording, or information storage and retrieval system, without permission in writing from the publisher. Address requests for permission to:

Phoenix Geophysics Limited, 3781 Victoria Park Avenue, Unit 3, Toronto, ON Canada M1W 3K5, or [email protected].

Information in this document is subject to change without notice.

MG-30, T-30 and the Phoenix logo are trademarks of Phoenix Geophysics Limited.

i i

Contents

Chapter 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 1About this guide . . . . . . . . . . . . . . . . . . . . . . . . 2

Intended audience . . . . . . . . . . . . . . . . . . . . . . 2

About the MG-30 . . . . . . . . . . . . . . . . . . . . . . . . 2

How to get further information andsupport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Important safety information . . . . . . . . . . . . 4Major Safety Concerns . . . . . . . . . . . . . . . . . . . . . . . . 4

High Power Output . . . . . . . . . . . . . . . . . . . . . . . . . . 4Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Batteries with Corrosive Electrolytes. . . . . . . . . . . . . . . . 4Carbon Monoxide Poisoning . . . . . . . . . . . . . . . . . . . . . 4Hot Surfaces and Exhaust . . . . . . . . . . . . . . . . . . . . . . 4Debris in Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5High Sound Pressure Levels . . . . . . . . . . . . . . . . . . . . . 5Wet Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . 5

Chapter 2: Preparing the MG-30 for field use . . . . . . . . . 7Positioning the MG-30 . . . . . . . . . . . . . . . . . . . 8

Setting up the exhaust pipe. . . . . . . . . . . . . . 8

Adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Adding engine oil . . . . . . . . . . . . . . . . . . . . . . . 9

Table 2-1: Engine oil grades . . . . . . . . . . . . . . . . . . . .10

Installing the battery . . . . . . . . . . . . . . . . . . .11

ii ii

Fuelling the MG-30 . . . . . . . . . . . . . . . . . . . . . 11

Connecting the transmitter . . . . . . . . . . . . . 12

Working in cold weather . . . . . . . . . . . . . . . .14Using the choke. . . . . . . . . . . . . . . . . . . . . . . . . . . . .14Preparing fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Working in hot weather . . . . . . . . . . . . . . . . .15Maintaining operating temperature . . . . . . . . . . . . . . .15

Chapter 3: Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Preparing to start the engine . . . . . . . . . . . 18Performing a safety check . . . . . . . . . . . . . . . . . . . . . 18Verifying the setup . . . . . . . . . . . . . . . . . . . . . . . . . . 18Preparing the transmitter . . . . . . . . . . . . . . . . . . . . . 18Priming the fuel system . . . . . . . . . . . . . . . . . . . . . . 19

Starting the engine . . . . . . . . . . . . . . . . . . . . .19

Transmitting with the T-30 . . . . . . . . . . . . . .20

Responding to warning lamps . . . . . . . . . . .21

Shutting down the MG-30 . . . . . . . . . . . . . . .22

Chapter 4: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 23Periodic maintenance . . . . . . . . . . . . . . . . . . 24Daily maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 24Every 100 operating hours . . . . . . . . . . . . . . . . . . . . 25Every 200 operating hours . . . . . . . . . . . . . . . . . . . . 25Every 400 operating hours . . . . . . . . . . . . . . . . . . . . 25Every two years . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Replacing the coolant . . . . . . . . . . . . . . . . . . .26

Replacing fuses . . . . . . . . . . . . . . . . . . . . . . . . .26

Storing the MG-30 . . . . . . . . . . . . . . . . . . . . . .27

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . .29

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Appendix A: Ignition wiring diagram and circuit schematic . . . . . . . . 35

Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

1 Chapter 1 1

Chapter

Introduction

This chapter provides an introduction to the MG-30 and tells you about:

• this guide and its intended audience.• the MG-30 in general.• how to get further information and support.• important safety information.

2 Chapter 1 About this guide 2

About this guideWelcome to the Phoenix MG-30™ Motor Generator User Guide.

This document is a guide to the MG-30, and provides setup and operation instructions, safety precautions, and maintenance procedures. Users should read the entire document before operating the MG-30 to ensure that the equipment is used correctly and safely.

Note Throughout this guide, “front” refers to the end of the MG-30 containing the control panel. The “left” and “right” sides are defined from a point of view facing the control panel.

Intended audienceThis Guide is intended for use by geophysicists and technicians familiar with electromagnetic techniques, and by automotive technicians who may be required to perform maintenance operations.

About the MG-30The MG-30 is a 40kVA, 208V, 3-phase motor generator consisting of a rotary automotive engine powering a modified aircraft alternator. It is intended to be used with the Phoenix T-30™ Geophysical Current Source (transmitter), which includes circuitry for controlling the output of the MG-30.

The MG-30 operates in two modes. In START mode, the motor can be started or idled (1000 to 1200 rpm), but the alternator does not output power. In RUN mode, the alternator output is controlled by the transmitter, and the motor runs at 4800 to 5000 rpm.

The transmitter control circuits regulate the power demand on the alternator by varying the alternator field current. As the load changes, a feedback circuit on the motor adjusts the throttle in order to maintain a constant alternator speed.

The motor is protected from overheating and loss of oil pressure. If the motor overheats, the MG-30 automatically switches to START mode, removing the

3 Chapter 1 How to get further information and support 3

load from the alternator. This condition is indicated by a HOT WATER lamp on the front panel. The motor idles in START mode until it cools to a safe operating temperature, then automatically returns to RUN mode.

If the engine oil pressure falls too low, the MG-30 will shut down completely, and indicate the condition by a LOW OIL lamp on the front panel.

Both protection features on the MG-30 turn off the high voltage output. If the controlling transmitter is transmitting at the time, the lack of high voltage input will trigger a transmitter fault indication (EM1-2).

The MG-30 is normally shipped “dry” with no fuel, coolant, lubricant, or battery installed. Chapter 2 explains how to prepare the motor generator for first use.

How to get further information and supportContact us at:

Phoenix Geophysics Limited 3781 Victoria Park Avenue, Unit 3Toronto, ONCanada M1W 3K5Telephone: +1 (416) 491-7340Fax: +1 (416) 491-7378e-mail: [email protected]

4 Chapter 1 Important safety information 4

Important safety information

Warning The MG-30 is a high-power motor generator, and can generate up to 30kVA. This level of electrical power can cause serious injury or death if mishandled. Please read and follow all the safety instructions provided by this documentation. Doing so will help insure the safety and well being of the equipment and personnel.

Major Safety Concerns

The major safety concerns specific to the operation of the MG-30 are:

High Power Output. At maximum power, the MG-30 output is 30kVA. This amount of electrical power can cause serious injury or death. Take appropriate safety precautions for personnel and spectators.

Fuel. There is a danger of fire and explosion when handling fuel and making fuel line connections. Ensure

that no one in the area is smoking and that the engine is turned off. Clean up all fuel spills immediately.

Batteries with Corrosive Electrolytes. Batteries contain an extremely corrosive electrolyte that can cause severe burns.

Carbon Monoxide Poisoning. Exhaust from the MG-30 must be properly vented. Do not run the MG-30 indoors unless an exterior exhaust system is added.

Hot Surfaces and Exhaust. Many components of the MG-30 can become very hot during use, including the engine, cooling systems, the metal housing and the exhaust system. Hot air that has passed through the alternator housing and an exhaust pipe shroud is vented from an opening below the right access panel. Stay clear of all hot surfaces and vents.

Debris in Housing. Tools or other objects may cause damage to the MG-30 or create a risk of fire, explosion or a short-circuit. Ensure before operating the MG-30 that there are no foreign objects inside the housing. Also ensure that the alternator air vent and radiator exhaust are not covered or blocked.


Chemicals. Coolant and lubricating oil are toxic and may also be very hot during and after use. Avoid contact with these chemicals. Clean up spills immediately, and wash your hands afterward.

High Sound Pressure Levels. Prolonged exposure to high sound pressure levels can result in permanent hearing loss. Personnel should wear hearing protection when working close to the MG-30.

Wet Weather. Moisture in the vicinity of a generator and transmitter can present an electrical hazard to personnel. Excessive moisture may damage the equipment. Take reasonable measures to minimize exposure of the MG-30 to rain and snow. Personnel should use extreme caution when operating electrical equipment in wet weather.

Shipping. The MG-30 is heavy and bulky and contains dangerous components including fuel, oil, and batteries that may have to be removed before shipping by commercial carriers. Proper arrangements must be made to ship the MG-30 without damage or danger.

Maintenance Procedures. Except where noted otherwise, never attempt to perform maintenance procedures while the MG-30 is running or is still hot. Always allow the system to cool to ambient temperatures before servicing any component.

On some modesl, the end plate of the alternator air filter is held in place by a set of threaded rods and nuts, and is located close beside the battery. To avoid accidental short circuits through metal tools, always disconnect the battery cables before servicing the air filter.

7 Chapter 2 7

Chapter

Preparing the MG-30 for field use

This chapter describes how to set up the MG-30 for use in geophysical data acquisition. Instructions are provided for:

• Positioning the MG-30.• Adding coolant and lubricant.• Installing the battery.• Fuelling the MG-30.• Connecting to the transmitter.• Adapting for extreme temperatures.

8 Chapter 2 Positioning the MG-30 8

Positioning the MG-30Place the MG-30 on a firm, level surface. If the unit is to be operated on a truck, be sure there is adequate clearance for the access panels to open fully, and for the radiator and alternator exhausts to operate unimpeded.

The access panels and the top of the MG-30 are equipped with brackets for the attachment of bungee cords. When working with the side panels open, always use a pair of bungee cords to hold the panels safely (see Figure 2-1).

Setting up the exhaust pipeFor convenience in shipping, the exhaust pipe is rotated to a horizontal position. It must be set up vertically before running the engine.

Fig. 2-1: Use bungee cords to hold side panel open safely.

To install the exhaust pipe:

1. Loosen the bolts on the clamp holding the last elbow section of the exhaust pipe.

2. Rotate the elbow section to the vertical position.

3. Tighten the clamp bolts securely. Do not overtighten.

The completed exhaust system is illustrated on the inside cover of this manual.

9 Chapter 2 Adding coolant 9

Adding coolantThe MG-30 must be protected from overheating and from freezing by using a 50-50 mixture of good quality ethylene glycol antifreeze and water.

Warning Never use plain water as the coolant, no matter what the operating or storage temperature. The MG-30 requires the anti-corrosion, lubricating, and other properties of antifreeze for protection and proper operation.

To add coolant:

1. Mix 10L of good quality antifreeze with 10L of distilled water.

2. Open the small access door located at the right rear of the top of the MG-30 and remove the radiator cap.

3. Slowly pour the antifreeze-water mixture into the radiator, until the liquid reaches the bottom of the overflow tube.

4. Replace the radiator cap and close the access door.

5. Open the left side access panel and add the antifreeze-water mixture to the overflow bottle on the side of the radiator until the liquid reaches the LOW mark.

6. Close the left side access panel.

Adding engine oilYou must add engine lubricating oil to the MG-30 before starting it for the first time. You must also add oil periodically during use, since rotary engines consume oil during normal operation.

To fill the MG-30 requires 5L of good quality synthetic or petroleum-based oil. Amsoil or Mobil 1 synthetic oils are recommended because they provide superior lubrication, lower operating temperatures, and twice the operating time between oil changes.

Choose the correct grade of oil using the table below.

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10 Chapter 2 Adding engine oil 10

To add engine oil:

1. Obtain 5L of the correct grade and type of engine oil.

2. Check that the sump drain plug is installed and tight. (The sump drain plug is at the end of a short length of flexible hose on the right underside of the engine.)

3. Open the left side panel of the MG-30 and remove the oil filler cap (see Figure 2-2 on page 10).

4. Pour the oil into the filler tube.

5. Replace the oil filler cap.

Fig. 2-2: Crankcase oil filler cap.

Table 2-1: Engine oil grades

Ambient Temperature

Oil Grade Oil Type

>35°C SAE 20W-50

>0°C SAE 10W–40 (preferred)

or SAE 10W–30

≤0°C SAE 5W–30 API Class SF, SG, or SH only

11 Chapter 2 Installing the battery 11

Installing the batteryThe MG-30 requires a 12V automotive battery for starting and to supply the alternator field current. Use a fully charged battery rated for 75AH or more.

To install the battery:

1. Remove the seven screws from the access panel below the controls, and lift the access panel away, revealing the battery tray on the left.

2. Loosen the nuts on the battery hold-down clamp.

3. Place the battery in the battery tray with the negative terminal toward the front of the MG-30.

4. Tighten the nuts on the battery hold-down clamp and ensure that the battery is securely held.

5. Attach the battery cable with the black sleeve to the negative battery terminal.

6. Attach the battery cable with the red sleeve to the positive battery terminal.

7. Replace the access panel and tighten the screws securely.

Fuelling the MG-30The MG-30 is powered by a gasoline engine, and can be fuelled with any unleaded gasoline of octane rating between 87 and 93, including fuels containing up to 10% ethanol (“gasohol”). Make sure the fuel is fresh and clean; filter out water and impurities before use if necessary.

12 Chapter 2 Connecting the transmitter 12

Fig. 2-3: Fuel hose.

To fuel the MG-30:

1. Place a tank containing fresh, clean gasoline next to the MG-30 on the left side.

2. Open the side panel, uncoil the rubber fuel hose (see Figure 2-3 on page 12) and guide it into the gap at the end the side panel hinge as you close the panel.

3. Place the end of the hose at the bottom of the fuel tank.

Warning To avoid damage to the fuel hose, take care that the side panel does not pinch the hose, and that no strain is placed on the hose where it rests on the panel.

Connecting the transmitterA special control cable and three high voltage output cables are supplied to connect the MG-30 to the controlling transmitter. The three AC input cables are bundled together, and terminate with Cam-Lok™ connectors on each end. The male connectors (uniform diameter) connect to the MG; the female connectors (stepped diameter) connect to the transmitter (see Figure 2-4).

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13 Chapter 2 Connecting the transmitter 13

Warning Before making any cable connections or disconnections, ensure that the MG-30 is either off or running in START mode only. Do not make or break connections when the MG-30 is in RUN mode.

Fig. 2-4: AC cable connectors. Note alignment arrows.

Note Take care to keep all cable connectors clean.

To connect the AC cables:

1. Locate the control cable terminal and the three high voltage output terminals on the right of the MG-30 control panel (see Figure 2-5).

Fig. 2-5: High voltage output terminals (3 upper connectors) and control cable terminal (bottom connector).

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Transmitter connector

MG connector

14 Chapter 2 Working in cold weather 14

2. At the MG-30 panel, hold the connectors with the alignment arrow facing up and push them all the way on to the output terminals.

3. Turn the connectors clockwise until they stop (approximately one-half turn).

4. Test the security of the connections by pulling on the connectors.

5. At the transmitter rear panel, repeat the process with the female connectors and the three AC INPUT terminals.

To connect the control cable:

1. Unscrew the protective cap on the CONTROL connector on the rear of the transmitter.

2. Aligning the key with the slot, insert the cable connector into the multi-pin connector and screw on the retainer.

3. Repeat the process at the control connector of the motor generator (see Figure 2-5).

Working in cold weatherThis section describes procedures and precautions to be aware of when working in cold temperatures (≤ 0°C).

Using the choke

The MG-30 is equipped with a choke for operation in cold weather. On models without a choke control on the front panel, the choke is completely automatic, and does not need to be set before starting. On models with a choke control on the front panel, pull the choke control out to start the engine and gradually push it back in as the engine warms up. Do not run the engine for long periods with the manual choke control pulled out.

15 Chapter 2 Working in hot weather 15

Preparing fuel

If very cold weather is expected, either add gasoline antifreeze to the fuel (0.5L gasoline antifreeze per 25L fuel), or use gasoline containing up to 10% ethanol.

Working in hot weatherThe MG-30 is protected from damage due to overheating, however some precautions should be taken to ensure good performance in high temperatures.

Maintaining operating temperature

When the engine is running under heavy load in hot weather, it may exceed a safe operating temperature. To help prevent overheating:

• ensure that the side panels are kept closed, to maintain proper airflow through the cabinet.

• ensure that nothing blocks the radiator exhaust at the rear or the alternator vent on the right side of MG-30.

Note: If the engine overheats during transmission (coolant temperature >105°C), the MG-30 automatically switches to START mode, removing the load from the alternator. This condition is indicated by a HOT WATER lamp on the front panel. The engine idles in START mode until it cools to a safe operating temperature, then automatically returns to RUN mode.

This condition will also trigger a safety shutdown of the T-30 if it is transmitting at the time. Refer to the T-30 User Guide for instructions on clearing the fault.

16 Chapter 2 Working in hot weather 16

17 Chapter 3 17

Chapter

Operations

This chapter describes the procedures necessary to use the MG-30 in the field:

• Preparing to start the engine.• Starting the engine.• Transmitting current with the T-30.• Responding to warning lamps.• Shutting down.

18 Chapter 3 Preparing to start the engine 18

Preparing to start the engineBefore the engine is started at each survey site, several procedures must be followed to ensure proper and safe operation.

Performing a safety check

Review the safety concerns described in the Introduction (see “Important safety information” on page 4). In particular:

• Keep open flames and smoking materials well clear of the fuel tank and engine.

• Stay clear of surfaces and vents that may become hot.

• Inspect the interior of the MG-30 and remove any tools or debris.

• Wear hearing protection in the near vicinity of the MG-30.

Verifying the setup

Review the setup instructions in Chapter 2. In particular:

• Ensure that the MG-30 is securely positioned on a level surface.

• Check the coolant level.• Check the oil level.• Check for signs of leaks: coolant, oil, or fuel.• Ensure that the fuel is fresh and clean, and

protected with gasoline antifreeze if appropriate.• Make cable connections to the controlling

transmitter (alternatively, you can do this while the MG-30 engine is warming up).

Preparing the transmitter

Turn on the T-30 control panel power using the switch at the rear of the cabinet, and make sure the OUTPUT switch is OFF. Refer to the T-30 User Guide for full instructions.

19 Chapter 3 Starting the engine 19

Priming the fuel system

The fuel hose will be filled with air when it is first put into the fuel tank. Follow this procedure to prime the fuel system.

To prime the fuel system:

1. Insert the ignition key in the control panel lock and turn it one position clockwise. (Do not turn it far enough to crank the engine.)

2. Listen for the hum of the fuel pump as it primes the system; when the hum stops, turn the ignition key off (counterclockwise one position).

3. Check the engine for any sign of fuel leaks. If any is found, take corrective action before continuing.

Starting the engineWhen the engine starts, there is no pressure in the oil system. The MG-30 is protected from damage due to low oil pressure during operation, so the protection

circuits must be bypassed for the first few seconds of running. This procedure explains how.

Fig. 1: Ignition control startup sequence.

To start the engine:

1. Follow all the procedures under “Preparing to start the engine” on page 18, and refer to Figure 1 above.

12

3

20 Chapter 3 Transmitting with the T-30 20

2. Ensure that the RUN/START switch is down, in the START position. (The engine can not be started in RUN mode.)

3. In cold weather, on models equipped with a manual choke, pull the choke control out.

4. Press the BYPASS switch up and hold it there.

5. Turn the ignition key two positions clockwise to crank the engine.

6. As soon as the engine catches, release the ignition key.

7. Observe the red LOW OIL lamp: when it goes out, release the BYPASS switch.

Note It should take no more than 15 seconds for the LOW OIL lamp to go out. If the lamp does not go out, note the oil pressure gauge reading, release the BYPASS switch and ignition key, and check the lubrication system for oil level and leaks.

8. Allow the engine to idle until the WATER TEMP gauge reads at least 120°F (50°C). If the manual choke has been pulled out, push it in gradually during this warm-up period.

Transmitting with the T-30Refer to the T-30 User Guide for complete instructions on setting up and operating the T-30 Current Source.

To transmit current:

• When the MG-30 has reached operating temperature (120°F or 50°C) and you are ready to begin transmitting, move the RUN/START switch up to the RUN position.

>120°F

21 Chapter 3 Responding to warning lamps 21

The engine speed will increase to 4800–5000 rpm, and the feedback circuit will maintain that speed while the transmitter varies the output load.

Note If the engine overheats during transmission (coolant temperature >107°C, 225°F), the MG-30 automatically switches to START mode, removing the load from the alternator. This condition is indicated by a HOT WATER lamp on the front panel. The engine idles in START mode until it cools to a safe operating temperature, then automatically returns to RUN mode.

This condition will also trigger a safety shutdown of the T-30 if it is transmitting at the time. Refer to the T-30 User Guide for instructions on clearing the fault.

• During pauses in transmitting, switch to START mode to idle the engine. However, avoid prolonged periods of idling. If you stop and restart the engine as required, engine wear and fuel consumption will be reduced.

Warning Do not disconnect the battery when the MG-30 is running. Do not allow the fuel tank to run dry.

Responding to warning lampsThe MG-30 has two warning lamps indicating fault conditions.

If the HOT WATER lamp lights during RUN mode, the MG-30 will automatically cool itself at idle, as described in the note above. If you have followed the instructions under “Working in hot weather” on page 14, no other action is necessary.

If the HOT WATER lamp lights during START mode, or fails to go out after several minutes of idling during automatic cool-down in RUN mode, stop the engine and service the cooling system.

If the LOW OIL lamp lights during RUN mode, or during START mode when idling, the MG-30 will shut down automatically. In this case, service the engine lubrication system.

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22 Chapter 3 Shutting down the MG-30 22

Shutting down the MG-30After operating the MG-30 under load, always allow the engine temperature to stabilize before shutting it down.

To shut down the MG-30:

1. Move the RUN/START switch down to START mode and let the MG-30 idle for 3–5 minutes.

2. Turn off the engine by turning the ignition key counterclockwise.

Warning Turning off the ignition while in RUN mode may cause backfiring and damage to the engine. Always put the MG-30 into START mode before turning off the ignition.

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23 Chapter 4 23

Chapter

Maintenance

To ensure long service life, the MG-30 must be properly maintained. This chapter provides information and instructions on:

• Periodic maintenance.• Electrical maintenance (fuse replacement).• Storing the MG-30.

24 Chapter 4 Periodic maintenance 24

Periodic maintenanceUnless specified otherwise, perform all maintenance procedures with the engine off and cool. Use the Maintenance Log on page 27 to record service operations.

Warning On some models, the end plate of the alternator air filter is held in place by a set of threaded rods and nuts, and is located close beside the battery. To avoid accidental short circuits through metal tools, always disconnect the battery cables before servicing the air filter.

Daily maintenance• Check the oil level and top up if necessary. Do not

overfill.• Check the coolant level and top up if necessary.• Check the alternator air filter for debris or dirt.

Clean or replace if necessary (then check the engine air filter, as it is therefore probably dirty, too).

Note The MG-30 is equipped with a permanent oiled-foam air filter element. It can be reused by periodically cleaning in solvent and re-oiling. To re-oil, use either motor oil or (in very dirty environments) aerosol foam filter oil made for the purpose.

• Inspect the engine for signs of leaking coolant, fuel, or oil. Repair as necessary.

Fig. 4-1: Engine oil sump drain hose (side panel removed for clarity).

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25 Chapter 4 Periodic maintenance 25

Every 100 operating hours• Check the engine and cabinet for loose bolts or

clamps and tighten as necessary.• Check both engine and alternator air filters for

debris or dirt. Clean or replace as necessary. (Perform this check more often in dusty conditions; less often in clean conditions.)

• If using petroleum-based engine oil, change the oil and oil filter. (Raise the MG-30 and set it level on blocks in order to access the crankcase drain plug, which is on the end of a short length of flexible hose on the right underside of the engine; see Figure 4-1 on page 24). Refer to “Adding engine oil” on page 9 for further specifications and procedures.)

Every 200 operating hours• Replace the alternator air filter and the fuel filter.• If using synthetic engine oil, change the oil and oil

filter. (Raise the MG-30 and set it level on blocks in order to access the crankcase drain plug, which is on the end of a short length of flexible hose on the

right underside of the engine; see Figure 4-1 on page 24). Refer to “Adding engine oil” on page 9 for further specifications and procedures.)

• Clean and re-oil the engine air filter.• Inspect and clean the distributor and the ignition

cables and replace if necessary.• Inspect the fan belt for wear or cracks and replace

if necessary.• Check fan belt tension.• Inspect the fan blades for chips or cracks, and

replace the fan if any defects are found.

Every 400 operating hours• Replace the spark plugs.• Inspect the distributor cap and rotor and replace if

necessary.

26 Chapter 4 Replacing the coolant 26

Every two years• Replace the coolant.• Check the condition and security of all hoses and

clamps.• Make a note of these operations in the Maintenance

Log on page 27.

Replacing the coolantA plastic hand pump with hose is supplied with the MG-30 for use when replacing the coolant.

To replace the coolant:

1. Remove the radiator cap.

2. Feed the hose of the supplied hand pump into the side of the radiator as far as possible.

3. Place the other end of the pump hose into a suitable container.

4. Squeeze the hand pump bulb to start the flow of coolant. If the container is lower than the radiator,

the coolant will syphon naturally. Otherwise, continue pumping.

5. Refill the cooling system as described on page 9.

6. Dispose of the used coolant according to local hazardous waste regulations.

Warning Engine coolant is poisonous. Treat it as hazardous waste and do not allow it to contaminate water supplies or groundwater. Do not leave it where humans or animals might accidentally ingest it.

Replacing fusesThe MG-30 is protected by a 20A fuse for the transmitter control and a 40A fuse for the ignition. If fuses blow frequently, contact Phoenix (see “How to get further information and support” on page 3).

Warning Always replace a blown fuse with a new one of the same kind and rating. Using the wrong fuse can result in hazards to personnel and damage to equipment.

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27 Chapter 4 Storing the MG-30 27

To replace the fuses:

1. Locate the fuse holders on the control panel, and unscrew them.

2. Replace any blown fuse with a new one of the same kind and rating.

3. Screw the fuse holders back into the control panel, taking care not to damage the threads.

Storing the MG-30Follow standard automotive procedures to protect the MG-30 when it will be stored for any length of time.

To prepare the MG-30 for storage:

1. If the storage period is likely to be longer than a few weeks, treat the engine with a storage oil fogger spray, following the instructions on the product label. (Suppliers of marine engines and parts usually carry storage oil spray.)

1. Change the engine oil and filter.

2. Check the air filters on the engine and alternator and clean or replace if necessary.

3. Replace the fuel filters.

4. Siphon off about 1L of coolant and check that it is clean; drain and replace the coolant if necessary. See “Adding coolant” on page 9.

Note Always mix the coolant (equal parts of distilled water and good quality antifreeze) before filling the system.

5. Remove the fuel supply and drain the fuel hose.

6. Open the side panels and drain the carburetor of fuel:

• On models equipped with a Holley carburetor, remove one lower bolt from each of the left and right float bowls (see Figure 4-2).

• On other models, remove one bolt from below the sight glass on each of the front and rear float bowls (see Figure 4-3 on page 28).

7. Replace the float bowl bolts.

8. Cover the MG-30 and store it in a cool, dry, dust-free environment.

28 Chapter 4 Storing the MG-30 28

Fig. 4-2: Holley carburetor drain bolt. Fig. 4-3: Non-Holley carburetor drain bolt.

29 Chapter 4 Maintenance Log 29

Maintenance LogUse the log that follows to record the service history of your MG-30. In the Notes areas, record the details of operating conditions (temperatures, pressures, etc.) as well as of maintenance procedures.

In-service. Date:

100 hours. Date: Hour meter:

Check engine and cabinet bolts.

Change petroleum-based engine oil.

Change oil filter.

Notes:




Change engine oil (petroleum-based or synthetic).

Change oil filter.

Replace alternator air filter; clean and oil engine air filter.

Replace fuel filters.

Inspect distributor.

Inspect ignition cables.

Inspect fan belt.

Check fan belt tension.

Inspect fan blades.

Notes:




Change oil filter.

Notes:





Change oil filter.

Replace the spark plugs.

Inspect the distributor cap and rotor.




Inspect fan belt.


Inspect fan blades.

Notes:




Change oil filter.

Notes:





Change oil filter.





Inspect fan belt.


Inspect fan blades.

Notes:




Change oil filter.

Notes:





Change oil filter.

Replace the spark plugs.

Inspect the distributor cap and rotor.




Inspect fan belt.


Inspect fan blades.

Notes:




Change oil filter.

Notes:





Change oil filter.





Inspect fan belt.


Inspect fan blades.

Notes:

Notes:

35 Appendix A 35

Appendix

Ignition wiring diagram and circuitschematic

36

Appendix A

36

37 Index 37

Index

Aadding coolant, 9antifreeze, 9antifreeze, gasoline, 15

Bbattery, 11bypass switch, 19

Cchoke, 14circuit schematic, 35cold weather, 14connecting the transmitter, 12control cable, transmitter, 13coolant, 9

Ddaily maintenance, 24diagram, wiring, 35

Eengine oil, 9engine speed, 21engine warm-up, 20engine, starting, 19exhaust pipe, setting up, 8

Ffault, transmitter, 3float bowls, carburetor, 27front, defined, 2fuel, 11fuel system, priming, 19fuses, 26

Ggasoline antifreeze, 15grade, engine oil, 9

Hhigh voltage output terminals, 13hot weather, 15

Iignition, 20ignition wiring diagram, 35indicators, warning lamps, 21

Llamps, warning, 21left side, defined, 2

Mmaintaining operating temperature, 15maintenance, 23maintenance log, 29

Ooil fogger spray, 27oil sump drain hose, 24oil types, 9operating temperature, maintaining, 15operations, 17overheating, 15

38 Index 38

Ppauses in transmitting, 21petroleum-based oil, 9Phoenix Geophysics Limited, contact

information, 3positioning the MG-30, 8preparing to start the engine, 18priming the fuel system, 19

Rreplacing fuses, 26right side, defined, 2run/start switch, 20

Ssafety check, 18safety information, 4schematic, circuit, 35shutting down the MG-30, 22starting the engine, 19storing the MG-30, 27support, contact information, 3synthetic oil, 9

Ttemperature, warm-up, 20transmitter fault, 3

transmitter, connecting, 12transmitting with the T-30, 20transmitting, pauses in, 21

Wwarning lamps, 21water temperature, 20weather considerations, 14wiring diagram, 35

ContentsIntroductionAbout this guideIntended audienceAbout the MG-30How to get further information and supportImportant safety informationMajor Safety ConcernsHigh Power OutputFuelBatteries with Corrosive ElectrolytesCarbon Monoxide PoisoningHot Surfaces and ExhaustDebris in HousingChemicalsHigh Sound Pressure LevelsWet WeatherShippingMaintenance Procedures

Preparing the MG-30 for field usePositioning the MG-30Setting up the exhaust pipeAdding coolantAdding engine oilTable 2-1: Engine oil gradesInstalling the batteryFuelling the MG-30Connecting the transmitterWorking in cold weatherUsing the chokePreparing fuel

Working in hot weatherMaintaining operating temperature

OperationsPreparing to start the enginePerforming a safety checkVerifying the setupPreparing the transmitterPriming the fuel system

Starting the engineTransmitting with the T-30Responding to warning lampsShutting down the MG-30

MaintenancePeriodic maintenanceDaily maintenanceEvery 100 operating hoursEvery 200 operating hoursEvery 400 operating hoursEvery two years

Replacing the coolantReplacing fusesStoring the MG-30Maintenance Log

Ignition wiring diagram and circuit schematicIndex

mg-30 user guide 2.2 - phoenix geophysics · 2010. 7. 20. · 2 chapter 1 about this guide 2 about...

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