Master Lock MGY5000C User Manual

PORTABLE DIESEL

GENERATOR

OWNER’S OPERATION AND INSTALLATION MANUAL

120 VOLTS

RESET TEST

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RESET

Generator Model: MGY5000C

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.

PORTABLE DIESEL GENERATOR

SAFETY INFORMATION

WARNINGS

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.

Carbon Monoxide Poisoning: 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:

severe personal injury, death, or substantial property damage if you ignore warning

WARNING:

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.

indicates a hazard which will cause

indicates a hazard which can cause

1. 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 al-

low 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.

2. Guard against fire hazard. Keep operation area well-vented. Keep generator at least three feet away from any object. Do not place flammable objects near generator.

• Do not use generator where flam-

mable 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.

Guard against electric shock. Generator produces high voltage. This high voltage can cause severe electric shock. Only responsible adults should use 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 con-

ductive 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.

4. Guard against burns. Hot engine parts can cause severe injury. 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 dur-

ing 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.

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

6. 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.

7. 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 wellvented area.

8. Battery contains sulfuric acid. Battery acid is poisonous if 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.

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OWNER’S MANUAL

SAFETY INFORMATION

Continued

Only a qualified electrical service person should service and 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.

10. Store generator in a well-vented area. Make sure fuel tank is empty. Never store with fuel in tank.

11. Never operate generator

• 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

12. Keep generator and nearby areas clean.

• Keep generator free of oil, mud, and

other foreign matter.

• Remove anything that creates slip-

pery 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 main-

tained. Be familiar with its use.

13. Know how to stop engine quickly. Know how to use all controls.

14. Prolonged exposure to loud noise can cause hearing loss.

•When working around generator,

wear approved hearing protection.

• Remember neighbors when using

generator.

PRODUCT IDENTIFICATION

Full Power Selector Switch

Roll Cage

Control Panel

120 Volt Receptacle

120 Volt Receptacle (GFCI)

120 Volt Receptacle (Duplex)

Hour Meter

120/240 Volt Receptacle

Decompression Lever

Starter Grip

120

O L

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TES

0 O

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120

/240

ENM

00000

005

U R S

1 /

Circuit Breaker

1 2

0 / 2

4 0

O L

T S

R E

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R E

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Electric Start Switch

Engine Run Lever

Engine Stop Lever

N U

O T S

Fuel Valve (under fuel tank)

Alternator

Battery Discharge

Oil Alert Lamp

Lamp

Fuel Gage

Fuel Cap

Fuel Tank

Ground Lug

Spark Arrester

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Engine

Figure 1 - Portable Generator

Muffler

Oil Dipstick

PORTABLE DIESEL 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 MGY5000C

Electrical

Rated Wattage* 5000 Rated Amperage

120 V 41.7 240 V 20.8

Receptacle

120-V,15-A Duplex Yes 120-V, 15-A GFCI Yes 120-V, 30-A Twist-Lock Yes 120/240-V, 20-A Twist-Lock Yes 120-V Full-Power Switch Yes

General

Yanmar Engine H.P. 10 Yanmar Engine Model L100 Fuel Type Diesel Fuel Tank Capacity 4.2 Gallons Oil Alert System Yes Electric Start Yes Weight (pounds) 241

* Single-phase, 1.0 power factor

UNPACKING

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 6, for installation instructions.

VENTILATION

DANGER: Use only in wellvented 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

WARNING: 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.

HIGH AND LOW TEMPERATURE OPERATION

Air temperature affects generator output. Output drops 1% for each 10° temperature rise above 60° F. Very low temperatures may make the engine hard to start. See engine owner’s manual for more information.

GENERATOR FEATURES

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 level falls too low.

If this system shuts down the engine, the engine will not start until you add oil. Add oil to engine (see Engine Oil, page 6).

See engine owner’s manual for more information.

BATTERY DISCHARGE LAMP

The battery discharge lamp (see Figure 2) 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.

Oil Alert

OIL

CHARGE

OFF

Lamp

Battery Discharge Lamp

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.

Figure 2- Battery Discharge Lamp and Oil Alert Lamp Location

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OWNER’S MANUAL

GENERATOR FEATURES

Continued

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.

120 VOLT ONLY Position

120/240 VOLT Position

Figure 3 - Full Power Selector Switch

IMPORTANT:

selector switch while powering electrical items. Unplug all items before moving switch. Failure to do so can damage switch.

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.

Do not move the full power

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

Note:

not receive serious injury. very small children may still be affected.

Infants and

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: 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 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.

Figure 4 - GFCI Receptacle

. IMPORTANT:

RESET

TEST

You must press

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 6.

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.

Normal Tripped

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.

Muffler

Clamp

Spark Arrester

Figure 6 - Installing Spark Arrester

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PORTABLE DIESEL GENERATOR

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 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:

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

Oil Level At Top Of Filler Neck

Dipstick

Oil

Figure 7 - Checking Oil Level

FUEL

WARNING: Diesel fuel presents a hazard of fire. Diesel fuel is flammable.

• Keep fuel out of children’s

reach.

•

Refuel generator in a wellvented 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. Al-

ways 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 con-

tainer. Store fuel in a wellvented 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.

See engine owner’s manual for more information.

BATTERY

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.

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

IMPORTANT:

nections are the correct polarity. This generators uses negative ground, 12-volt DC starting system.

This generator has and electric starter. A battery is not supplied with generator. You must provide a 12-volt, 32-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.

Make sure battery con-

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