Master Lock MGY5000 User Manual

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PORTABLE DIESEL

GENERATOR

OWNER’S OPERATION AND INSTALLATION MANUAL

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

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.

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

SAFETY

INFORMATION

Continued

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-

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

SAFETY

INFORMATION

Continued

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.

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

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

Fuel Tank

Ground Lug

Spark Arrester

Muffler

Oil Dipstick

Figure 1 - Portable Generator

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.

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.

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

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.

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.

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.

TrippedNormal

Muffler

Clamp

Spark Arrester

Figure 6 - Installing Spark Arrester

ENGINE OIL

We ship the generator without oil in the engine crankcase. You must add oil before starting engine. See engine owner’s manual for specific oil type.

CHECKING OIL LEVEL AND ADDING OIL

Follow steps below to check oil level. Make sure engine is level and stopped.

1. Remove either dipstick (see Figure 7). Wipe dipstick clean.

2. Insert dipstick into oil filler neck. Do not screw it in. Oil level should be at top of filler neck. Oil should cover most of dipstick.

3. If level is low, fill to top of oil filler neck (see Figure 7). Only use oil recommended in engine owner’s manual.

NOTE:

engine from restarting.

If oil level is too low, oil alert system will shutdown engine and prevent

Oil Level At Top Of Filler Neck

Dipstick

Oil

Figure 7 - Checking Oil Level

FUEL

WARNING ICON G 001

WARNING

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 engine. 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.

Use clean, fresh, diesel fuel. Use diesel fuel with cetane rating of 45 or higher. Avoid getting dirt, dust, or water in fuel tank.

BATTERY

See engine owner’s manual for more information.

WARNING

Battery gives off explosive gases. Keep sparks, flames, and 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.

WARNING

Battery contains sulfuric acid. 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.

• If battery acid gets on your skin, wash with water.

• If battery acid gets in your eyes, flush with water at least 15 minutes. Call a doctor at once.

Battery acid is poisonous.

• If swallowed, drink large amounts of water or milk. Follow with milk of magnesia or vegetable oil. Call a doctor at once.

Continued

BATTERY

Continued

CAUTION

WARNING ICON G 001

If you remove battery, insulate the red, positive (+) battery cable terminal. Insulate with electrical tape. Exposed terminal may spark when generator runs.

IMPORTANT:

Make sure battery connections are the correct polarity. This

generator use negative ground, 12-volt DC starting system. This generator has an electric starter. A battery is not supplied with generator. You

must provide a 12-volt, 45-amp-hour battery. The positive and negative battery cables are supplied with generator. You must install these cables before mounting battery.

Always wear safety glasses when working with battery. Make sure battery terminals are clean. Make sure cable connections are tight.

Always shut down engine before removing or attaching battery cables. Always remove the negative (–) cable first. Always attach negative (–) cable last.

INSTALLING BATTERY CABLES TO ENGINE

1. Attach the red, positive (+) battery cable to the starter solenoid on engine (see Figure 8).

2. Attach the black, negative (–) battery cable to the engine block. Use the bolt, nut, and two washers provided with the battery cables. Attach cable as shown in Figure 9.

Starter Solenoid

Red, Positive (+) Battery Cable

Figure 8 - Connecting Red, Positive (+) Battery Cable

to Starter Solenoid on Engine

Black, Negative (–) Battery Cable

Figure 9 - Connecting Black, Negative (–) Battery Cable to Engine Block

BATTERY

Continued

MOUNTING BATTERY TO GENERATOR

1. Secure battery to generator by battery hold-down system. This system consists

of the battery mounting bracket, hook bolts, and nuts (see Figure 10).

2. Locate the red, positive (+) battery cable from starter solenoid. Connect it to

the positive (+) battery terminal (see Figure 11).

3. Locate the black, negative (–) battery cable attached to engine block. Connect

it to the negative (–) battery terminal (see Figure 11).

4. Check battery before starting engine. Make sure fluid levels are full. Make sure

battery is charged.

See engine owner’s manual for more information.

Nut

Battery Mounting Bracket

Battery

Figure 10 - Battery Hold-Down System

Red, Positive Cable From Starter Solenoid

Black, Negative

Cable From

Engine Block

Hook Bolt

Figure 11 - Connecting Positive and Negative Cables to Battery

GENERATOR

WARNING ICON G 001

GROUNDING

CAUTION

You must properly earth-ground generator before starting. This will help guard against deadly electric shock. Only use grounded plugs with generator. Only use grounded extension cords. Only use three-wire or double-insulated power tools.

Grounding generator helps prevent electric shock from a ground fault condition. Locate ground lug on end of generator housing (see Figure 12). Attach a #10 stranded-copper ground wire to ground lug. Drive grounding point into ground. Grounding point can be a stake, grounding rod, or pipe. Grounding point should be copper or brass. Attach ground wire to grounding point. You must supply the ground wire and grounding point. They do not come with generator. Follow the National Electrical Code and all state and local codes. Consult your power company or a licensed electrician.

CAUTION

For a grounding point, do not use metal pipe being used to carry combustible materials or gases.

Alternator

Ground Lug

Ground Wire

Copper or Brass Grounding Point

Figure 12 - Grounding Generator

EXTENSION

CORDS

Only use grounded extension cords. Be sure to use extension cord with proper wire gauge size. See chart below.

Recommended Minimum Wire

Gauges (AWG) for Extension Cords

Ampere AWG for Length of Cord in Feet

Load 50' 100' 150'

2181818 3181818 4161616 5161616 6161614

8161412 10 16 14 12 12 14 14 12 14 14 12 10 16 12 12 10 20 10 10 8

STANDBY

INSTALLATION

TO HOME OR

BUILDING

WARNING

WARNING ICON G 001

Have standby installation performed by a skilled, licensed electrician. Do not let anyone else wire into a utility circuit. Personal injury, equipment damage, or damage to home could occur.

IMPORTANT:

electric service is more than 60 amps. This will exceed generator output. Only power needed items during a power outage. Make sure total wattage of electrical load does not exceed rated wattage of generator.

You can use this generator as a standby power source. During a power outage, the generator will power selected items in a building. Have generator and additional wiring installed by a skilled, licensed electrician. This is not a do-it-yourself job. Follow all local codes.

This generator will not power your entire home. Most home utility

WARNING

WARNING ICON G 001

The electrician must install a double-throw transfer switch. This isolates existing electrical circuits from the utility power line. If not isolated, generator output will back-feed into utility power line. This may electrocute a power company line repair person.

DETERMINING

ELECTRICAL

LOAD FOR

GENERATOR

You must decide what electrical load your generator can power. Do this before using generator. Use the following four-step method. It will help you select a load that is not too large. Make sure total wattage of all electrical loads does not exceed 5000 watts. Electric motors present a special problem when figuring load. Read Step 3 carefully.

1. Make two lists of items you want powered by generator. List all motors and motor-powered appliances in one. List all lights, small appliances, etc. in the other. For standby service to home or building, only include items you must power.

2. Enter running watts of each item except motors. The light bulb or appliance

Note:

nameplate lists its wattage. Remember, 1KW = 1000 watts.

The nameplate may not list wattage. It may only list volts and amps. The formula for finding wattage is: Volts x Amps = Watts. For example: An appliance nameplate states 3 amps at 120 volts. 3 amps x 120 volts = 360 watts.

3. Electric motors present a special problem. They require up to 3-times their rated wattage to start. Chart 2, below, shows starting watts for different size motors. For example: an electric motor nameplate states 5 amps at 120 volts. 5 amps x 120 volts = 600 watts running. Multiply this figure by 3. This will show the starting watts needed. 600 watts x 3 = 1800 watts to start. When figuring the generator load for motors, you must use the starting watts figure.

Note:

Do not use the running watts figure.

Some motors require nearly the same wattage to run as to start. These items include saws, drills, hair dryers, and food mixers. See Chart 1 for typical appliance wattage examples.

4. Add watts and starting watts of all items. This total must not be larger than 5000 watts. It is a good idea to have up to 25% extra capacity for future needs or extra equipment.

Chart 1—Typical Electric Appliance Wattages

Running Starting

Equipment Watts Watts

Light bulb (100W) 100 100 Radio 150 150 Fan 200 600 Television 400 400 Furnace fan Vacuum cleaner 600 750 Sump pump Refrigerator/freezer 800 2400 6" Circular saw 800 1000 Floodlight 1000 1000

(1/3 hp) (1/3 hp)

600 1800 700 2100

Equipment Watts Watts

1/2" Drill 1000 1250 Toaster 1200 1200 Coffee maker 1200 1200 Skillet 1200 1200 14" Chain saw 1200 1500 Water well pump

(1/2 hp) 1000 3000

Hot plate/range

(per burner) 1500 1500

Water heater 5000 5000

Running Starting

Chart 2

Approximate Starting Watts*

Motor Approximate Universal Repulsion Split

HP Running Motors Induction Capacitor Phase

Rating Watts (small appliance) Motors Motors Motors

1/8 275 400 600 850 1200 1/4 400 500 850 1050 1700 1/3 450 600 975 1350 1950 1/2 600 750 1300 1800 2600 3/4 850 1000 1900 2600 x

1 1000 1250 2300 3000 x

1 1/2 1600 1750 3200 4200 x

2 2000 2350 3900 x x

* – Always use starting watts, not running watts, when figuring correct electrical load. x – Motors of higher horsepower are not generally used.

OPERATION

GENERAL INFORMATION

This generator is not large enough to power your entire home. Do not connect generator to any existing electrical circuits. Plug items directly into generator receptacles. Do not exceed amperage rating of receptacles. Only use grounded cords.

DANGER

WARNING ICON G 001

WARNING

WARNING ICON G 001

Never connect generator to any existing electrical circuits. The 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.

Note:

We supply the engine owner’s manual with generator. Refer to that manual

for questions concerning engine operation.

USING RECEPTACLE

Note:

Do not exceed amperage rating of receptacles. Exceeding rating will trip

receptacle circuit breaker. Use receptacles properly. Improper use could damage generator. Use only

grounded extension cords. Power only grounded or double-insulated items. Do not overload receptacles. This generator has the following receptacles (see Figure 13):

• 120V, 15-amp GFCI duplex receptacle

• 120V, 30-amp twist-lock receptacle

• 120/240V, 20-amp twist-lock receptacle

RESET

120V, 30-Amp Twist-Lock

120 VOLTS

120V, 15-Amp GFCI Duplex

120/240V, 20-Amp

FULL POWER

SELECTOR

Twist-Lock

120 240V

120/240 VOLTS

RESET

TEST

120

ONLY

RESET

Figure 13 - Receptacle Locations

Continued

OPERATION

Continued

POWER CORD AND PLUG REQUIREMENTS

120V, 30-amp twist-lock receptacle

• NEMA L5-30P plug

• Three-wire, 30-amp cord

120/240V, 20-amp twist-lock receptacle

• NEMA L14-20P (20-amp) plug

• Four-wire, 20-amp cord

120 Volt

30 Amp

Ground (Green)

(Neutral)

120/240 Volt

20 Amp

Ground (Green)

(Hot)

Neutral

120V 120V

Ground

L5-30P Plug

L14-20P Plug

(Hot)

Figure 14 - Cord and Plug Configurations

(Neutral)

OPERATION

Continued

PRESTART

Operate generator on a firm, dry, and clean surface. The surface must be level. Protect generator from heavy dust, sand, dirt, rain, or snow. Do not locate generator near standing water and snow. Make sure area is well-vented.

WARNING

WARNING ICON G 001

Only responsible adults should use generator. Never let anyone operate generator without proper instructions.

Note:

If oil level is too low, oil alert system will keep engine from starting (see Oil

Alert System, page 8). Make sure oil level is full before starting. See Engine Oil,

page 12. Before starting engine, disconnect all electric loads from generator. You may need to bleed fuel line to remove trapped air

• if starting engine for first time

• if starting engine after allowing generator to run out of fuel

Follow the directions below to bleed fuel line.

BLEEDING FUEL LINE

1. Loosen fuel line clamp and remove fuel line from engine. Place open end of

fuel line over a clean container to catch any fuel spilled in step 3, below.

2. Move fuel valve lever to the “O” (open) position (see Figure 15, page 22).

3. Allow air to bleed from line. When fuel exits fuel line in a steady stream,

reattach fuel line to engine.

4. Add spilled fuel back into fuel tank.

STARTING

CAUTION

WARNING ICON G 001

You must always run the engine at full speed. Do not run engine at lower speeds. At full speed, the engine runs at 3600 RPM under load. The engine must maintain 3600 RPM for generator to create correct voltage. Running engine at lower speeds will damage generator and powered items.

Continued

OPERATION

Continued

IMPORTANT:

Never start generator with electrical loads connected. Start engine

before adding electrical loads.

1. Make sure fuel tank is full. See Fuel, page 13 for fuel information.

2. Move fuel valve lever to the “O” (open) position (see Figure 15).

3. Move engine run lever to the RUN position (see Figure 16).

Fuel Valve Lever

Figure 15 - Fuel Valve Lever In “O” (open) Position

Engine Run Lever

RUN

STOP

Figure 16 - Engine Run Lever In RUN Position

4. Start the engine.

A. Electric Starter

I. Push decompression lever all the way down (see Figure 17). Decompres-

sion lever will stay in this position until you turn starting key.

II. Turn the starting key clockwise to the START position (see Figure 18).

Hold it there until engine starts.

III. When engine starts, release key.

IMPORTANT:

Do not use electric starter more than ten seconds. Starter motor damage may occur. If engine fails to start, release the key and wait 15 seconds. After 15 seconds, try starting again.

Decompression Lever

OIL

Starting Key

OIL

CHARGE

OFF

Figure 17 - Decompression Lever

Figure 18 - Starting Key

Continued

OPERATION

Continued

In cold weather, your engine may be hard to start. If so, remove the rubber plug on the rocker arm cover (see Figure 19). Add 2 cc of engine oil in hole. Replace rubber plug. Repeat starting procedure.

WARNING

WARNING ICON G 001

Never use gasoline, paint thinner, or any other flammable liquid as a starting aid. An explosion may occur.

CAUTION

WARNING ICON G 001

Keep rubber plug on rocker arm in place when not adding oil for starting. Rain, dirt, and other debris may enter the engine. This can damage the engine.

Engine Starting

Rubber Plug

OIL

Oil Hole

Figure 19 - Rubber Plug On Rocker Arm Cover

B. Recoil Starter

I. Slowly pull starter rope until you feel strong resistance. Gently return

starter rope to engine.

II. Push decompression lever all the way down (see Figure 20). Decompres-

sion lever will stay in this position until you pull starter rope.

Decompression Lever

OIL

Figure 20 - Decompression Lever

Continued

OPERATION

Continued

III. Firmly grasp starter grip with both hands. Remove slack from starter rope

by lightly pulling starter grip.

IV. To start engine, pull starter rope briskly. You must pull the starter rope all

the way out. If not, the engine will not start.

IMPORTANT:

gently. This will prevent damage to starter. In cold weather, your engine may be hard to start. If so, remove the rubber plug

on the rocker arm cover (see Figure 19, page 23). Add 2 cc of engine oil in hole. Replace rubber plug. Repeat starting procedure.

Never use gasoline, paint thinner, or any other flammable liquid as a starting aid. An explosion may occur.

Keep rubber plug on rocker arm in place when not adding oil for starting. Rain, dirt, and other debris may enter the engine. This can damage the engine.

If engine does not start, repeat steps under B. Recoil Starter on page 23.

HIGH ALTITUDE OPERATION

This generator will not perform well at high altitudes without proper adjustment. Contact a Yanmar dealer for adjustment information.

Do not let starter grip snap back against engine. Return it

WARNING

WARNING ICON G 001

CAUTION

WARNING ICON G 001

ADDING ELECTRICAL LOADS

IMPORTANT:

loads does not exceed rated wattage of generator. Overloading may shorten generator life. It could also cause internal damage to generator. Overloading will trip circuit breaker.

IMPORTANT:

if only powering 120V items. Only move switch to 120/240 VOLT position if powering 240V items.

1. Check items to be powered. Their nameplate lists their wattage ratings.

Note:

may require up to 3-times their rated wattage to start. You must figure total electrical load wattage. Make sure total wattage of all electrical loads does not exceed rated wattage of generator. See Determining Electrical Load For Generator, page 18.

2. Start engine. Let engine reach full speed.

3. Connect electrical loads one at a time. If the load consists of electric motors, start them first. Always start the largest first. Start each motor individually.

Do not overload generator. Make sure total wattage of all electrical

Keep full power selector switch in the 120 VOLT ONLY position

The wattage ratings for some electrical motors are misleading. They

OPERATION

Continued

DISCONNECTING ELECTRIC LOADS

Remove electrical loads one at a time. Remove voltage sensitive items first. Voltage sensitive items include TVs, VCRs, and other home electronic items.

STOPPING ENGINE

Follow the steps below to stop engine.

1. Remove all electrical loads from generator (see Disconnecting Electrical

Loads, above). Remove electrical loads one at a time.

2. Let engine run for two or three minutes after removing electrical loads. This

lets engine cool slightly.

3. Push down engine stop lever (see Figure 21). This releases engine run lever

and stops engine. Do not stop engine with the decompression lever.

4. Turn the starter key to the OFF position.

5. Turn fuel valve lever off. Do this by moving valve lever to the “S” position

(see Figure 22).

6. Slowly pull starter rope until you feel strong resistance. Gently return starter

rope to engine. This action closes the intake and exhaust valves. This prevents rust from forming while not using engine.

RUN

STOP

Engine Stop Lever

Figure 21 - Pushing Down Engine Stop Lever

Fuel Valve Lever

Figure 22 - Fuel Valve Lever In “S” Position

MAINTENANCE

WARNING ICON G 001

AND REPAIRS

WARNING

WARNING ICON G 001

Only a qualified electrical service person should service and repair the alternator on this generator. Use only factory approved replacement parts.

CAUTION

Shut off generator before performing maintenance.

STORAGE

IMPORTANT:

Keep generator level when servicing. Never turn generator upside

down or stand it on end to service.

Note:

We supply the engine owner’s manual with generator. Refer to that manual

for questions concerning engine maintenance and repairs. Non-engine parts require little maintenance. Keep generator clean. Use a damp

cloth to clean outside surfaces. Never use water to clean generator. Water can cause damage to internal parts. Use vacuum to clean air inlet and outlet louvers of alternator.

WARNING

Remove all fuel from fuel tank before storing generator. Store fuel in approved container. Store fuel in a well-vented area free of open flames or sparks.

WARNING

The muffler becomes very hot during operation. The muffler remains hot for a while after shutdown. Let engine cool before storing.

IMPORTANT:

Keep generator level while in storage. Never store generator upside

down or standing on end.

Note:

We supply the engine owner’s manual with generator. Refer to that manual

for questions concerning engine storage. Cover and store generator in a clean, dry place. Do not expose generator to extreme

high or low temperatures during storage.

TROUBLE-

Note:

See engine owner’s manual for engine troubleshooting.

SHOOTING

Only a qualified electrical service person should service and repair generator. Use only factory approved replacement parts.

OBSERVED PROBLEM

No voltage when starting generator with no electrical load

Voltage is less than normal voltage with no electrical load

WARNING

WARNING ICON G 001

POSSIBLE CAUSE

1. Defective capacitor

2. Winding short circuit or loose connections

3. Defective rotor diode

4. Loss of residual magnetism

1. Engine speed too low

2. Clogged spark arrester

3. Defective rotor diode

4. Partial short circuit in winding

5. Defective capacitor

REMEDY

1. Replace capacitor

2. Check resistance of coils (see

Electrical Component Specifications, below)

3. Replace both diodes on rotor

4. Apply 12-volt battery to capacitor terminals for 2-3 seconds

1. Set engine speed to 3720 RPM (62 Hz) with no load

2. Clean arrester. See engine owner’s manual

3. Replace both diodes on rotor

4. Check resistance of coils (see

Electrical Component Specifications, below)

5. Replace capacitor

ELECTRICAL

COMPONENT

SPECIFICA-

TIONS

Voltmeter reading more than 10% high with no electrical load

Voltmeter reading correct with no electrical load, but more than 10% low when electrical load is added

Stator Stator Rotor Rotor Capacitor,

Main Auxiliary Primary Secondary MFD Diodes (2)

Model Winding * Winding ∆Winding † Winding † 450 Volt 800 Volt

MGY5000 0.54 1.38 0.61 2.29 50 70 Amp

* Connect T2 (green) and T3 (black). Measure resistance between T1 (red) and T4 (yellow). ∆ Resistance between brown and white leads. † Remove diodes to check resistance.

1. Engine speed too high

1. Defective rotor diode

2. Electrical load too high

3. Engine not running properly

Resistance in Ohms

1. Set engine speed to 3720 RPM (62 Hz) with no load

1. Replace both diodes on rotor

2. Do not overload generator

3. Contact an authorized engine service center

WIRING

DIAGRAMS

Capacitor

White

Green/Yellow

Circuit

Breaker

25A

Circuit

Breaker

25A

Yellow

Black

Red

White

T1 T2T3T4

120/240V 20A

Receptacle

White

Black

Green

Red

Black Black

Black

Main

Windings

Red

Black

White

Selector

Run

Light

Full Pwr

Switch

Yellow

Red

Diode

Rotor

White

120V, 15A

Receptacle

Black

Red

Auxiliary

Phase

Diode

GFCI

HOT

LINE

Green

WHITE

White

Stator

Brown

120V, 30A

Receptacle

Green

T1 T2 T3 T4

110/120V

Circuit

Breaker

20A

Stator

220/240V

110/120V

Charge

Coil

Figure 23 - Alternator Wiring Diagram

Green/White

Black

Green/White

Regulator

Bridge

Green

Charge

Yellow

White

Fuse

Starter

White Red

Motor/

Solenoid

Red

Black

Battery

Red

Relay

Red White

Low Oil

Pressure Lamp

2 3 4 1

Shutdown

Solenoid

Red

White

Green

Yellow

Key

Switch

Green Yellow

White

Red

Oil Pressure Switch

Black

Charge

Lamp

Black

Figure 24 - Engine Wiring Diagram

TECHNICAL

SERVICE

You may have further questions about installation, operation, or troubleshooting. If so, contact DESA International’s Technical Service Department at 1-800-323-

5190.

SERVICING

THE ENGINE

REPLACEMENT

PARTS

For Yanmar engine replacement parts, contact Parts Company of America at 1800-323-0620. Yanmar engine servicing should be handled by your nearest authorized Yanmar engine service firm. Contact Yanmar at 1-714-630-9415 for nearest authorized Yanmar engine service firm.

Note:

Use only original replacement parts. This will protect your warranty cover-

age for parts replaced under warranty.

Parts Under Warranty

Contact authorized dealers of this product. If they cannot supply original replacement part(s), call DESA International’s Technical Service Department at 1-800-323-5190.

When calling DESA International, have ready

• your name

• your address

• model number of your generator

• how generator is malfunctioning

• purchase date

Usually, we will ask you to return the defective part to the factory.

Parts Not Under Warranty

Contact authorized dealers of this product. If they can’t supply original replacement part(s), call DESA International’s Parts Department at 1-800-972-7879.

ACCESSORY

When calling DESA International, have ready

• model number of your generator

• the replacement part number

Heavy-Duty Wheel Kit – PA2000

Wheelbarrow-style wheel kit. Makes generator easy for one person to move. This kit includes:

• Large 12-inch wheels for easy rolling

• Plated tubing and hardware for long life

• Long handles with thick grips for greater comfort and control

Complete installation instructions included.

ILLUSTRATED

PARTS LIST

Alternator Assembly

KEY PART

NO. NUMBER DESCRIPTION QTY.

099723-02 Alternator Assembly 1 1 099844-01 End Cover 1 2 099701-01 Screw, M5 x 13 6 3 099760-01 Bushing 1 4 099863-01 Terminal Block (4-block) 1 5 099863-02 Terminal Block (2-block) 1 6 17587000 Ground Lug 1 7 M11084-26 Screw, #10-16 x 3/8" 1 8 099847-02 Stator Bolt 4 9 WLE-5 Lock Washer, 5/16" 4

10 099843-01 Bearing Housing 1 11 27005003S Capacitor 1 12 * Stator 1 13 27003002 Fan Bracket 1 14 27003015S Screw, M8 x 20 4 15 27001010S Rotor Nut 1 16 27003013S Washer 1 17 099842-02 Draw Bolt 1 18 27003003 Bearing 1 19 27003012S Diode 2 20 * Rotor 1 21 27003008 Fan 1 22 101839-01 Engine Flange 1 23 26322004 Bolt, 3/8-16 x 5/8" 4 24 WLE-6 Lock Washer, 3/8" 4 25 099892-01 Foam Pad 1

* - Part not available by itself. Must purchase Alternator Assembly.

ILLUSTRATED

PARTS LIST

Fuel Tank and Roll Cage

9 8

KEY PART

NO. NUMBER DESCRIPTION QTY.

1 099935-01 Fuel Tank Assembly 1 2 HC4-6C Screw, 1/4-20 x 3/4" 4 3 WP-4C Washer, 1/4" 4 4 NTC-4C Nut, 1/4-20 4 5 099943-01 Roll Cage 1 6 099945-01 Spreader 1 7 04110002 Bolt, 5/16-18 x 1 1/2" 2 8 WP-5C Washer, 5/16" 5

9 NEC-5C Nut, 5/16-18 9 10 26302006 Screw, 1/2-20 x 1" 2 11 WLI-8 Lockwasher, 1/2" 2 12 17529000 Shock Mounts 2 13 26007004 Bolt, 5/16-18 x 3/4" 5 14 WLE-5 Washer, 5/16" 3

8 14

KEY PART

NO. NUMBER DESCRIPTION QTY.

15 26020000 Shock Mount 1 16 099749-01 Battery Bracket 1 17 099750-01 Hook Bolt 2 18 14138000 Ground Strap 1 19 M10908-74 Screw, 1/4-20 x 1/2" 2 20 100410-01 Screw, #8-10 x 1/2" 4

PARTS AVAILABLE - NOT SHOWN

099947-01

Safety Information

Decal 099948-01 Operation Decal 1 099873-01 Battery Cable

(Positive) 1 099873-02 Battery Cable

(Negative) 1

ILLUSTRATED

PARTS LIST

Control Panel

120 VOLTS

RESET

TEST

ONLY

120

FULL POWER

SELECTOR

120/240 VOLTS

120

240V

RESET

KEY PART NO. NUMBER DESCRIPTION QTY.

1 100148-05 Control Panel 1 2 22616009 Circuit Breaker, 20 Amp * 1 3 099833-01 120V, 30A Twist-Lock Receptacle * 1 4 100445-01 120V, 15A Duplex (GFCI) Receptacle * 1 5 099956-01 Full Power Selector Switch * 1 6 22616011 Circuit Breaker, 25 Amp * 2 7 099834-01 120/240V, 20A Twist-Lock Receptacle * 1 8 099804-01 Lamp 1 9 099760-01 Bushing 1 10 24306006 Screw, #8-18 x 1/2" 4 11 100149-01 Control Box 1 12 22261000 Speed Nut, #8 8 13 WLI-2BL Lock Washer, #8 4 14 099997-01 Switch Plug 1

PARTS AVAILABLE - NOT SHOWN

100177-01 Panel Schematic Decal 1

* Includes fastening hardware

ILLUSTRATED

PARTS LIST

Switch Control Box

4 5

KEY PART

NO. NUMBER DESCRIPTION QTY.

1 100131-01 Switch Control Box 1 2 22721000 Low Oil Light 1 3 099936-01 Key Switch, Lamp,

and Harness Assy. 1

4 24306006 Hex-Head Screw,

#8-18 x 1/2" 4 5 WLI-2BL Lock Washer, #8 4 6 22261000 Speed Nut, #8 4 7 26498000 Relay 1 8 NTF-3C Hex Lock Nut, #10-32 1 9 RN12000100 Adhesive-Backed PVC

Foam 1

10 24478004 Connector Cover 1 11 24477004 Connector 1 12 M10908-3* Hex Tapping Screw,

#6-32 x 1/2" 1

13 WLI-1C* Internal Tooth Lock

Washer, #6 6

KEY PART NO. NUMBER DESCRIPTION QTY.

14 26509000 Full Bridge 1 15 M10908-27 Hex Tapping Screw,

#10-32 x 1/2" 1 16 15020000 Grommet 1 17 WP-3C Flat Washer, #10 1 18 26499000 Hex-Head Screw,

#10-32 x 3/4" 1 19 26490000 Solenoid 1 20 26494000 Hex-Head Screw,

M4 x 8 2 21 26492000 Hex-Head Screw,

M3 x 8 4 22 100132-01 Switch Control Box

Bracket 1 23 100085-01 Female T-Tap

Connector 1 24 099760-01 Strain Relief Bushing 1

* Available from your local hardware store

PARTS

CENTRALS

These Parts Centrals are privately owned businesses. They have agreed to support our customer’s needs by providing original replacement parts and accessories.

Baltimore Electric

1348 Dixwell Avenue Hamden, CT 06514 1-800-397-7553 203-248-7553 Parts Department

Parts Company of America

1657 Shermer Road Northbrook, IL 60062 1-800-323-0620 708-498-5900 Parts Department

Portable Heater Parts

342 N. County Rd. 400 East Valparaiso, IN 46383 All States 1-800-362-6951 219-462-7441

FBD

601 Hope Street Bowling Green, KY 42101 1-800-654-8534 502-796-8406

Master Service Center

1184 Wilson NW Walker, MI 49504 1-800-446-1446 616-791-4760

LA Porte’s Parts & Service

2444 North 5th Street Hartsville, SC 29550 803-332-0191 Parts Department

MTA Distributors

2940 Foster Creighton Drive Nashville, TN 37204 1-800-264-0225 615-726-2225

Tuco Industrial Products

P.O. Box 5076 Lynwood, WA 98046 1-800-735-1268 206-743-9533 Parts Department

NOTES

WARRANTY INFORMATION

KEEP THIS WARRANTY

Model Serial No. Date Purchased

Always specify model and serial numbers when communicating with the factory. We reserve the right to amend these specifications at any time without notice. The only warranty applicable is our standard

written warranty. We make no other warranty, expressed or implied.

Note:

The two-year limited warranty below covers all non-engine parts of this generator including the alternator. Yanmar

warrants the engine. See engine owner’s manual for engine warranty information.

TWO-YEAR LIMITED WARRANTY

PORTABLE GENERATORS

DESA International warrants each alternator, generator, or electric product of its manufacture, to be free from defects in material and workmanship for two years from the date of ﬁrst purchase from an authorized dealer, provided that the product has been properly installed, maintained, and operated in accordance with all applicable instructions. The bill of sale or proof of purchase must be presented at the time a claim is made under this warranty.

This warranty is extended only to the original retail purchaser. This warranty covers only the parts and labor required to restore this unit to its proper operating condition. Warranty parts must be obtained through factory authorized dealers and service centers for this product. These dealers and service centers will provide original factory replacement parts. Failure to use original factory replacement parts voids this warranty.

This warranty does not apply to parts that are not in original condition because of normal wear and tear, or parts that fail or become damaged as a result of misuse, abuse, negligence, accident, lack of proper maintenance, alteration, modification, tampering, contaminated fuels, repair using improper parts, or repair by anyone other than an authorized dealer or service center. Routine maintenance is the responsibility of the owner. Travel, handling, transportation, and incidental costs associated with warranty repairs are not reimbursable under this warranty and are the responsibility of the owner.

DESA International makes no warranty with respect to the engine and engine components not of its manufacture. They are subject to warranties of their manufacturers.

To the full extent allowed by the law of the jurisdiction that governs the sale of the product, this express warranty excludes any and all other expressed warranties and limits the duration of any and all implied warranties, including warranties of merchantability and fitness for a particular purpose to two years from the date of first purchase, and DESA International’s liability is hereby limited to the purchase price of the product and DESA International shall not be liable for any other damages whatsoever including indirect, incidental, or consequential damages.

Some states do not allow limitation of how long an implied warranty lasts or an exclusion or limitation of incidental or consequential damages, so the above limitation of damages may not apply to you.

This warranty provides the original purchaser with specific rights. For information regarding those rights, please consult the applicable state laws.

2701 Industrial Drive

INTERNATIONAL

P.O. Box 90004 Bowling Green, KY 42102-9004

100380-01 REV. C 2/95

Master Lock MGY5000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual