Master Lock MGY5000C User Manual

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PORTABLE DIESEL

GENERATOR

OWNER’S OPERATION AND INSTALLATION MANUAL

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120 VOLTS

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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.

R

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.

3.

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.

2

107359

OWNER’S MANUAL

SAFETY
INFORMATION

Continued

9.

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

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/240

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Circuit
Breaker

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Electric Start
Switch

Engine Run
Lever

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Engine
Stop
Lever

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Fuel Valve
(under fuel tank)

Alternator

Battery
Discharge

Oil Alert
Lamp

Lamp

Fuel Gage

Fuel Cap

EF

Fuel Tank

Ground
Lug

Spark
Arrester

107359

Engine

Figure 1 - Portable Generator

3

Muffler

Oil Dipstick

R

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.

4

Figure 2- Battery Discharge Lamp and Oil
Alert Lamp Location

107359

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.

20

20

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

107359

5

R

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-

6

107359