Magnum Boots MPG 3800 User Manual
PORT ABLE GENERA T OR
MPG 3800
OPERA TING/PARTS MANUAL
This manual provides information and procedures to safely operate and maintain the engine and generator. 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. An engine operator’s manual was also supplied with the unit at the time of shipment
from the factory . The manual provides det ailed operation and maintenance procedures for the engine.
Additional copies of this 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
Engine Make:
Engine Serial Number:
Engine Model Number:
Generator Make:
Generator Model Number:
Generator Serial Number:
Unit Model Number:
Unit Serial Number:
WARNING
CALIFORNIA PROPOSITION 65 WARNING:
Engine exhaust and some of its constituents are known to the state
of California to cause cancer, birth defects and other reproductive harm.
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TABLE OF CONTENTS
INTRODUCTION ..............................................................................................................................2
T ABLE OF CONTENTS ...................................................................................................................3
SAFETY NOTES.............................................................................................................................4
OPERA TING SAFETY.....................................................................................................................4
ENGINE SAFETY ...........................................................................................................................5
ELECTRICAL SAFETY....................................................................................................................5
UNIT SERIAL NUMBER LOCA TION ................................................................................................6
SAFETY SYMBOL SUMMARY.......................................................................................................7
SPECIFICA TIONS ...........................................................................................................................8
COMPONENT LOCA TIONS.............................................................................................................9
CONTROL P ANEL COMPONENTS...............................................................................................10
GROUNDING THE GENERAT OR .................................................................................................. 11
CONNECTING ELECTRICAL LOADS ............................................................................................ 11
GFCI TEST INSTRUCTIONS ......................................................................................................... 11
PREVENTION OF OVERLOAD..................................................................................................... 11
WA TT AGE CONSUMPTION OF EQUIPMENT...............................................................................12
USE OF EXTENSION CORDS ......................................................................................................12
EXTENSION CORD SELECTION CHART ......................................................................................13
ADDING ENGINE OIL ...................................................................................................................13
ADDING GASOLINE .....................................................................................................................13
ST ARTING THE ENGINE...............................................................................................................14
POWERING THE LOADS .............................................................................................................14
STOPPING THE ENGINE .............................................................................................................15
MAINTENANCE SCHEDULE ........................................................................................................16
DAIL Y MAINTENANCE CHECKS AND TIPS .................................................................................16
LIFTING THE GENERAT OR ..........................................................................................................16
UNIT DECALS...............................................................................................................................17
CONTROL P ANEL ASSEMBL Y..............................................................................................18 - 19
FRAME AND FUEL T ANK ASSEMBLY ..................................................................................20 - 21
ENGINE AND GENERATOR ASSEMBL Y...............................................................................22 - 23
AC WIRING DIAGRAM..................................................................................................................24
DC WIRING DIAGRAM..................................................................................................................25
Page
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 personal injury or death, damage to equipment, or improper service.
The following formatting options will apply when calling the readers attention to the DANGERS, WARNINGS, CAUTIONS, NOTICES and NOTES.
Indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.
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
NOTICE
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 generator 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 generator. The following points should be practiced at
all times:
• The area immediately surrounding the generator should be dry, clean, and free of debris.
• NEVER start a unit in need of repair.
• NEVER operate the generator if any of the following conditions exist during operation:
1. Noticeable change in engine speed.
2. Loss of electrical output.
3. Equipment connected to the generator overheats.
4. Sp arking occurs.
5. Engine misfires or there is excessive engine/generator vibration.
6. Operating on a combustible surface.
7. Protective covers are loose or missing.
8. If the ambient air temperature is above 1 10° F .
4
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. Read and follow all safety
warnings described in the engine operator’s 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.
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 touch or lean against hot exhaust or engine parts.
• DO NOT clean air filter with gasoline or other types of low flash point solvents.
• Keep hands, feet and loose clothing away from moving parts on the generator and engine.
• If equipped with electric start, generator 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.
ELECTRICAL SAFETY
While the engine is running, potentially lethal voltages are present at the outlets located on the control
panel. Failure to follow the safety guidelines described below could result in severe injury or death.
• Only a qualified and licensed electrician should make connections to the generator.
• NEVER wash the unit with any high pressure hoses or power washers.
• NEVER allow water to accumulate around the base of the unit. If water is present, DO NOT service!
• NEVER service electrical components if clothing or skin is wet. If the unit is stored outside, check the
engine and generator for any moisture and dry the unit before use.
• NEVER start the engine with any of the circuit breakers switched on or with any loads connected to
the control panel. Serious generator damage will result.
• ALWAYS disconnect the NEGATIVE (-) battery cable from the corresponding terminal before performing any service on the engine, generator or any other components. Remove the NEGATIVE (-) battery
cable from the corresponding terminal if the unit is to be stored or transported.
5
UNIT SERIAL NUMBER LOCATION
Refer to the location illustrated below to find the unit ID tag. Important information, such as the unit serial and model
number are found on this tag. Record the information from this tag, so it is available if the tag is lost or damaged.
When ordering parts or requesting technical service information, you may be asked to specify this information.
Unit ID Tag
215 Power Drive • Berlin, WI 54923
1-800-926-9768
MODEL
MPG 3800
SERIAL NUMBER
000000
kglbs. amb. temp.
rpm hz phase
CONTINUOUS
kW
120/240 120/240
V
A
28.3/14.2
kW
V
A
1 Ø
MAXIMUM
31.7/15.8
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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 section of this
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.
Hot surface(s) nearby.
Two-person lift only.
Check oil level daily.
Stop engine before fueling.
Asphyxiation hazard; Operate
in well ventilated area.
Dangerous voltage may be
present. Disconnect battery
before servicing.
Use unleaded gasoline only.
G
Unit electrical ground.
Fire/explosion hazard; Keep
open flames away from unit.
Lift here only.
Read and understand the
supplied operator’s manual
before operating unit.
7
SPECIFICATIONS
Read this manual carefully before attempting to use this generator. 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.
SPECIFICA TIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.
MAGNUM MODEL MPG 3800
Generator Specifications
Generator Frequency .................................................................................60 Hz
Maximum Output Watts .............................................................................3800
Continuous Output Watts...........................................................................3400
Main Circuit Breaker...................................................................................16 Amp-2 pole
Maximum Amps .........................................................................................32A
Engine Specifications
Engine Make..............................................................................................Honda
Engine Model ............................................................................................. GX240
Power - net prime* .....................................................................................7.1 hp (5.3 kW)
Fuel Consumption - net prime .................................................................... 1.47 gph (5.56 Lph)
Approximate Run time................................................................................9.7 hours
Recoil Start ................................................................................................ Yes
Electric Start..............................................................................................No
Capacities
Fuel T ank ................................................................................................... 6.6 gal. (25 L)
Weights and Dimensions
Dry Weight................................................................................................. 185 lbs (84 kg)
Operating Weight .......................................................................................226 lbs (103 kg)
Dimensions ................................................................................................ 36.8 x 21.4 x 21.5 in
Dimensions ................................................................................................ 934.7 x 543.6 x 546.1 mm
Dimensions, Wheel Kit Option ................................................................... 36.8 x 27.0 x 27.0 in
Dimensions, Wheel Kit Option ................................................................... 934.7 x 686.0 x 686.0 mm
* The power rating of the engine indicated in this document is the net power output tested on a production engine for
the engine model and measured in accordance with SAE J1349 at 3600 rpm. Mass production engines may vary
from this value. Actual power output for the engine inst alled in the final machine will vary depending on numerous
factors, including the operating speed of the engine in application, environmental conditions, maintenance, and other
variables.
36.8 in.
22.0 in.
21.5 in.
27.0 in.
21.4 in.
8
A
COMPONENT LOCATIONS
FUEL LEVEL
GAUGE
IR FILTER
HOUSING
CENTRAL
LIFTING EYE
FUEL TANK
CAP
CONTROL
PANEL
FUEL SHUT
OFF VALVE
(UNDER TANK)
RECOIL
STARTER
ENGINE
STARTING
BATTERY
HANDLE -
WHEEL KIT
(OPTIONAL)
ENGINE CHOKE
(UNDER TANK)
BATTERY
TRAY
(OPTIONAL)
ENGINE
EXHAUST
WHEEL KIT
(OPTIONAL)
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