Master Lock MGY5000 User Manual
R
PORTABLE DIESEL
GENERATOR
OWNER’S OPERATION AND INSTALLATION MANUAL
EF
120 VOLTS
RESET
RESET
TEST
FULL POWER
SELECTOR
120/240 VOLTS
120
ONLY
RESET
120
240V
RESET
RUN
STOP
Generator Model: MGY5000
IMPORTANT
Read and understand this manual before operating or servicing
generator. Improper use of generator can cause serious injury.
Keep this manual for future reference.
CONTENTS
SECTION PAGE
Safety Information........................................................................... 3
Product Identification ...................................................................... 6
General Information ........................................................................ 7
Specifications .................................................................................. 7
Unpacking........................................................................................ 7
Ventilation ....................................................................................... 8
Dust, Dirt, Rain, and Snow.............................................................. 8
High and Low Temperature Operation............................................ 8
Generator Features........................................................................... 8
Oil Alert System ....................................................................... 8
Battery Discharge Lamp ........................................................... 9
Full Power Selector Switch....................................................... 9
Ground Fault Circuit Interrupter Receptacle ........................... 10
Electric Start............................................................................. 10
Receptacle Circuit Breaker ...................................................... 11
Spark Arrester .......................................................................... 11
Engine Oil....................................................................................... 12
Fuel ................................................................................................. 13
Battery ............................................................................................ 13
Generator Grounding...................................................................... 16
Extension Cords.............................................................................. 17
Standby Installation To Home or Building .................................... 17
Determining Electrical Load For Generator................................... 18
Operation ........................................................................................ 19
General Information................................................................. 19
Using Receptacle ..................................................................... 19
Power Cord and Plug Requirements ........................................ 20
Prestart ..................................................................................... 21
Bleeding Fuel Line................................................................... 21
Starting ..................................................................................... 21
High Altitude Operation .......................................................... 24
Adding Electrical Loads .......................................................... 24
Disconnecting Electrical Loads ............................................... 25
Stopping Engine....................................................................... 25
Maintenance and Repairs ............................................................... 26
Storage ............................................................................................ 26
Troubleshooting.............................................................................. 27
Electrical Component Specifications ............................................. 27
Wiring Diagrams ............................................................................ 28
Technical Service ........................................................................... 29
Servicing the Engine....................................................................... 29
Replacement Parts .......................................................................... 29
Accessory ....................................................................................... 29
Illustrated Parts Lists ................................................................... 30-33
Warranty Information ........................................................ Back Cover
2
SAFETY
!
WARNING ICON G 001
INFORMATION
!
WARNINGS
WARNING ICON G 001
IMPORTANT: Read this owner’s manual and the engine owner’s
manual carefully. Become familiar with this generator before trying to
operate or service it. Know its uses, limitations, and any hazards
involved. Improper use of generator can cause severe injury or death
from explosion, fire, burns, electrical shock, or carbon monoxide
poisoning.
DANGER
Carbon monoxide poisoning may lead to death!
Engine exhaust contains poisonous carbon monoxide gas. Overexposure will
cause loss of consciousness and will lead to death. Use only in well-vented areas.
Make sure area has plenty of free-moving, fresh, outside air. Never run generator
in an enclosed or confined area. Never run generator inside occupied building.
Early signs of carbon monoxide poisoning resemble the flu, with headaches,
dizziness, and nausea. If you have these signs, get fresh air at once! Some people
are more affected by carbon monoxide than others. These include pregnant
women, persons with heart or lung disease or anemia, those under the influence of
alcohol, and those at high altitudes. Make certain you read and understand all
warnings. Keep this manual for reference. It is your guide to safe and proper
operation of this generator.
Safety information appears throughout these instructions. Pay close attention to
them. Below are definitions for the safety information listed throughout this
manual.
DANGER indicates a hazard which will cause severe personal injury,
death, or substantial property damage if you ignore warning.
WARNING indicates a hazard which can cause severe personal injury,
death, or substantial property damage if you ignore warning.
CAUTION indicates a hazard which will or can cause minor personal
injury or property damage if you ignore warning.
!
1.
DANGER Diesel fuel presents a hazard of fire. Diesel fuel is flammable.
• Keep fuel out of children’s reach.
• Refuel generator in a well-vented area. Do not fill fuel tank in the dark. Do
not refuel while engine is running. Unhook all electrical loads and shut off
engine before refueling.
• Do not overfill fuel tank. Always allow room for fuel to expand. If you
overfill tank, fuel can overflow onto hot generator. This can cause fire.
After refueling, tightly close fuel tank cap.
• Do not spill fuel. If fuel spills, make sure area is dry before starting engine.
• Never smoke in refueling area. Never allow open flames or sparks in area.
• Store fuel in approved container. Store fuel in a well-vented area free of
open flames or sparks.
Continued
3
SAFETY
INFORMATION
Continued
!
2.
3.
WARNING
Keep generator at least three feet away from any object. Do not place flammable objects near generator.
• Do not use generator where flammable vapors are present. Some vapors are
heavier than air. These vapors settle in low-lying places.
• Do not use generator in enclosed spaces. This includes motor home or RV
generator compartments.
!
WARNING
age. This high voltage can cause severe electric shock. Only responsible adults
should use the generator.
• Properly ground generator before starting.
• Never let anyone operate or service generator without proper instructions.
• Avoid contact with live terminals or bare wires.
• Do not use generator outdoors in rain or snow.
• Do not use generator near standing water or snow.
• Do not use if generator is wet or damp.
• Do not use generator in highly conductive areas. These areas include metal
decking and steelwork.
• Only use grounded extension cords.
• Do not use any worn or damaged electric cords. Electric shock or damage to
generator may result.
• Do not wear damp clothing or wet shoes when using generator.
Guard against fire hazard. Keep operation area well-vented.
Guard against electric shock. Generator produces high volt-
!
4.
5.
6.
7.
WARNING
Use caution and remain alert when using generator.
• Keep children and animals away from generator while it is running or hot.
• Keep all covers and shields in place. Keep them tightly secured.
• The muffler becomes very hot during operation. The muffler remains hot
for a while after shutdown. Do not touch muffler while it is hot. Do not let
muffler touch anything flammable. Let engine cool before transporting or
storing.
!
WARNING
licensed electrician. Do not let anyone else wire into a utility circuit. Personal
injury, equipment damage, or damage to home could occur.
!
WARNING
generator output will back-feed into the utility power line. This may electrocute a power company line repair person. Also, if generator is powering
electrical circuits, the chance of an electrical fire exists.
!
WARNING
cigarettes away. Do not remove or install battery cables when engine is
cranking or running. Only service or use battery in a well-vented area.
Guard against burns. Hot engine parts can cause severe injury.
Have standby installation to home or building performed by a
Never connect generator to any existing electrical circuits. The
Battery gives off explosive gases. Keep sparks, flames, and
4
SAFETY
INFORMATION
Continued
!
8.
9.
10.
11.
WARNING
swallowed. Contact with skin or eyes may cause severe burns. Do not tilt
generator with battery installed. Tilting could cause battery acid to spill.
Wear protective clothing and face shield when servicing. Keep out of
children’s reach.
!
WARNING
repair generator.
• Generator produces high voltage. Use extreme caution when working on
electrical parts.
• When working on generator, avoid hot muffler, exhaust manifold, and
engine parts. Severe burns may occur.
• Do not work on generator when tired.
• Use only factory approved replacement parts.
!
WARNING
empty. Never store with fuel in tank.
!
CAUTION
• if engine speed changes greatly
• if engine misfires often
• if powered items overheat
• if electrical output drops
• if it is sparking
• if it produces smoke or flames
• if it vibrates at high levels
• if it has a damaged receptacle
Battery contains sulfuric acid. Battery acid is poisonous if
Only a qualified electrical service person should service and
Store generator in a well-vented area. Make sure fuel tank is
Never operate generator
!
12.
13.
14.
CAUTION
• Keep generator free of oil, mud, and other foreign matter.
• Remove anything that creates slippery areas around generator.
• Remove oily rags and other items that create fire hazards.
• Keep a fire extinguisher nearby. Make sure it is rated ABC by the NFPA.
They are good for all uses. Consult your local fire department.
• Keep fire extinguisher well maintained. Be familiar with its use.
!
CAUTION
controls.
!
CAUTION
• When working around generator, wear approved hearing protection.
• Remember neighbors when using generator.
Keep generator and nearby areas clean.
Know how to stop engine quickly. Know how to use all
Prolonged exposure to loud noise can cause hearing loss.
5
PRODUCT
IDENTIFICATION
Roll Cage
Control
Panel
120 Volt
Receptacle
120 Volt
Receptacle
(GFCI)
Full Power
Selector Switch
120/240 Volt
Receptacle
Run Lamp
120 VOLTS
RESET
RESET
TEST
120
ONLY
Circuit
Breaker
Engine
Run Lever
EF
Engine
Stop Lever
FULL POWER
SELECTOR
120/240 VOLTS
RESET
120
240V
RESET
RUN
STOP
Oil Alert
Lamp
Battery
Discharge
Lamp
Electric Start
Switch
Alternator
Fuel Valve
(under fuel
tank)
Decompression
Lever
Starter Grip
Engine
Fuel Gage
Fuel Cap
EF
Fuel Tank
Ground
Lug
Spark
Arrester
Muffler
Oil Dipstick
Figure 1 - Portable Generator
6
GENERAL
INFORMATION
This portable generator is rugged and compact. It provides dependable, trouble-free
service. The alternator is brushless with revolving fields. Yanmar diesel engine
provides long life under heavy use. This engine is governed to maintain engine
speed of 3600 RPM under load. 3600 RPM engine speed provides 120/240V, 60
Hz power.
Additional Features
• Circuit breaker protection
• Spark-arresting muffler
• Large fuel tank
• Oil alert system
• Electric starter
• Pressurized lubrication system
• 15-Amp ground fault circuit interrupter (GFCI) receptacle
SPECIFICATIONS
MODEL MGY5000
Electrical Specifications
Rated Wattage* 5000
Rated Amperage
120 Volt 41.7
240 Volt 20.8
Receptacle Specifications
120-Volt, 15-Amp GFCI Yes
120-Volt, 30-Amp Twist-Lock Yes
120/240-Volt, 20-Amp Twist-lock Yes
120-Volt Full-Power Switch Yes
General Specifications
Yanmar Engine H.P. 9
Yanmar Engine Model L90
Fuel Type Diesel
Fuel Tank Capacity 4.2 Gallons
Oil Alert System Yes
Electric Start Yes
Weight (pounds) 241
UNPACKING
* Single-phase, 1.0 power factor
1. Remove generator from carton.
2. Remove any protective packaging applied to generator for shipment.
3. Check for loose or missing parts. Check for shipping damage. If any parts are
missing or damaged, promptly inform dealer where you bought generator.
4. Battery cables are in a separate bag inside generator carton. You must install
these cables to engine. See Battery, page 13 for installation instructions.
7
WARNING ICON G 001
VENTILATION
WARNING ICON G 001
DANGER
Use only in well-vented areas. Make sure area has
plenty of free-moving, fresh, outside air. Never run
generator in an enclosed or confined area. Never run
generator inside occupied building. Engine exhaust
contains poisonous carbon monoxide gas.
Overexposure will cause loss of consciousness and
will lead to death.
This generator needs cooling air to run properly. Never block free-flowing, cooling
air to generator. Overheating will occur without cooling air. This will damage the
generator. Keep generator at least three feet away from any object.
DUST, DIRT,
RAIN, AND
SNOW
HIGH AND LOW
TEMPERA TURE
OPERATION
GENERA T OR
FEATURES
DANGER
Do not use generator outdoors in rain or snow. Do
not use generator near standing water or snow. Do
not use if generator is wet or damp. Operating
generator in these conditions increases the risk of
electrocution. Severe injury or death can occur.
Do not use generator in extremely dusty or dirty conditions. This will severely
affect its life. Keep generator clean. Do not allow dust, dirt, rain, or snow to collect
on it. Protect generator from outdoor elements.
Air temperature affects generator output. Output drops 1% for each 10° temperature rise above 60° F. Low temperatures may make the engine hard to start. See
engine owner’s manual for more information.
OIL ALERT SYSTEM
The oil alert system protects the engine from low oil damage. This system automatically shuts down the engine and prevents engine restarting if the oil pressure
falls too low.
If this system shuts down the engine, the engine will not start until you add oil. The
oil alert lamp is near engine starter switch (see Figure 2, page 9). Add oil to engine
(see Engine Oil, page 12).
See engine owner’s manual for more information.
8
GENERATOR
FEATURES
Continued
Oil Alert
Lamp
OIL
CHARGE
OFF
Battery
Discharge
Lamp
Figure 2 - Battery Discharge Lamp and Oil Alert Lamp Location
BATTERY DISCHARGE LAMP
The battery discharge lamp (see Figure 2, above) will light if battery charger is not
operating while engine is running. If this happens, the battery will not charge and
will eventually run down. Have battery charging circuit repaired by authorized
service person.
FULL POWER SELECTOR SWITCH
The full power selector switch is on the control panel. The switch has two positions: 120 VOLT ONLY, and 120/240 VOLT.
120 VOLT ONLY: This position sends full power to the 120V receptacles only.
240V power is not available. Use this position when powering 120V items only.
120/240 VOLT: This position sends full power to the 120/240V receptacle. It also
powers the 120V receptacles at reduced wattage capacity.
120V
ONLY
120 VOLT ONLY
IMPORTANT:
FULL POWER
SELECTOR
120
240V
Position
Figure 3 - Full Power Selector Switch
Do not move the full power selector switch while powering
FULL POWER
SELECTOR
120V
ONLY
120/240 VOLT
Position
120
240V
electrical items. Unplug all items before moving switch. Failure to do so can
damage switch.
Continued
9
GENERATOR
FEATURES
Continued
GROUND FAULT CIRCUIT INTERRUPTER RECEPTACLE
This generator has a 120-volt ground fault circuit interrupter (GFCI) receptacle.
The GFCI receptacle is on the control panel. The GFCI protects you against
hazardous electrical shock caused when your body becomes a path through which
electricity travels to reach ground. This could happen when you touch an appliance or cord that is ‘live’ through faulty mechanism, damp or worn insulation, etc.
When protected by the GFCI, you may still feel a shock, but the GFCI should cut
it off quickly. A person in normal health should not receive serious injury.
Infants and very small children may still be affected.
Test Procedure
Check the GFCI receptacle every month. This insures it is working right.
1. Push black TEST button. Red RESET button should pop out. This should trip GFCI,
resulting in no electrical power at receptacle. Verify this by plugging test lamp
with good bulb into receptacle. If lamp does not work, GFCI receptacle is good.
!
WARNING
WARNING ICON G 001
If RESET button does not pop out, do not use the GFCI
receptacle. Contact a qualified electrician for repairs.
2. If the GFCI receptacle tests okay, restore power by pushing the RESET button
back in. The test lamp should work at this time.
press the RESET button firmly and fully. It should lock into place. If the GFCI
does not lock into place, do not use receptacle. Contact a qualified electrician
for repairs.
IMPORTANT:
You must
Note:
RESET
TEST
Figure 4 - GFCI Receptacle
ELECTRIC START
This model has an electric starter. A battery is not supplied with generator. You
must provide a 12-volt, 45-amp-hour battery. For more battery information, see
Battery, page 13.
10
GENERATOR
FEATURES
Continued
RECEPTACLE CIRCUIT BREAKER
The circuit breakers protect the receptacles and alternator. Overloading generator
will trip circuit breaker. A short circuit in item being powered will also trip
breaker. If this occurs, unplug electrical load from receptacle. Let circuit breaker
cool down. Push circuit breaker button to reset.
Electric motors need higher starting current. They require up to three-times their
rated wattage to start. The starting current needed may be too high. This can cause
nuisance circuit breaker tripping. To help prevent this, start electric motors first.
Connect additional items to generator after starting motors. If this continues to
happen, reduce the total generator load.
20
Figure 5 - Receptacle Circuit Breaker Button
SPARK ARRESTER
We ship a spark arrester with this generator. You must install spark arrester to
muffler (see Figure 6).
A spark arrester is required if using generator in a national forest and other designated state and local areas. Check local codes.
The spark arrester needs periodic cleaning. A dirty spark arrester reduces engine
output and increases fuel consumption. It also makes starting difficult. See engine
owner’s manual for cleaning instructions.
20
TrippedNormal
Muffler
Clamp
Spark
Arrester
Figure 6 - Installing Spark Arrester
11
Loading...