Master Lock MGY5000C User Manual

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PORTABLE DIESEL

GENERATOR

OWNER’S OPERATION AND INSTALLATION MANUAL

120 VOLTS

RESET TEST

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120/240 VOLTS

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HOURS 1/10

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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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

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/240

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Circuit Breaker

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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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OWNER’S MANUAL

BATTERY

Continued

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

MOUNTING BATTERY TO GENERATOR

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.

Battery Mounting Bracket

Nut

GENERATOR GROUNDING

WARNING: 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. These do not come with generator. Follow the National Electrical Code and all state and local codes. Consult your power company or a licensed electrician.

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

Black, Negative (–) Battery Cable

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

107359

Battery

Hook Bolt

Figure 10 - Battery Hold-Down System

Red, Positive Cable From Starter Solenoid

Black, Negative Cable From Engine Block

Figure 11 - Connecting Positive and Negative Cables to Battery

Ground Lug

Copper or Brass Grounding Point

Alternator

Figure 12 - Grounding Generator

Ground Wire

PORTABLE DIESEL 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

Load Cord in Feet

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: 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.

WARNING: 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 5,000 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 nameplate lists its wattage. Remember, 1KW = 1000 watts. 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

Note:

The

problem. They require up to threetimes their rated wattage to start. Chart 2, page 9, 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. Do not use the running watts figure.

Note:

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, page 9, for typical appliance wattage examples.

4. Add watts and starting watts of all items. This total must not be larger than 5,000 watts. It is a good idea to have up to 25% extra capacity for future needs or extra equipment.

IMPORTANT:

power your entire home. Most home utility 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 may need to 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

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OWNER’S MANUAL

DETERMINING ELECTRICAL LOAD FOR GENERATOR

Continued

Chart 1 - Typical Electric Appliance Wattages

Chart to be used as reference. Data may vary wiht size, make, and/or model.

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)

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 10" Table saw 2000 6000 Water heater 5000 5000

Chart 2

Approximate Starting Watts*

Motor Approximate Universal Repulsion Split

HP Running Motors Induction Capacitor Phase

Rating Watts (small appliance) Motors Motors Motors

1/8 500 625 1100 1500 2250 1/4 700 875 1550 2100 3150 1/3 800 1000 1750 2400 3600 1/2 1100 1375 2400 3300 4950 3/4 1400 1750 3100 4200 x

1 1700 2125 3750 5100 x

/2 2100 2625 4620 6300 x

2 2450 3075 5400 x x

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

Running Starting

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.

WARNING: 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 doubleinsulated items. Do not overload receptacles. This generator has the following receptacles (see Figure 13):

• 120V, 15-amp duplex receptacle

• 120V, 15-amp GFCI duplex receptacle

• 120V, 30-amp twist-lock receptacle

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

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Continued

PORTABLE DIESEL GENERATOR

OPERATION

Continued

120V, 15-Amp GFCI Duplex

120V, 15-Amp Duplex

120 V

LTS

120V, 30-Amp Twist-Lock

Figure 13 - Receptacle Locations

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

Figure 14 - Cord and Plug Configurations

120/240V, 20-Amp Twist-Lock

FULL POWER

120 ONLY

SELECTOR

120/240V

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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: 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 4). Make sure oil level is full before starting. See Engine Oil, page 6.

Before starting the 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).

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: 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.

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

IMPORTANT:

Never start generator with electrical loads connected. Start engine before adding electrical loads.

1. Make sure fuel tank is full. See Fuel,

page 6, for fuel information.

2. Move fuel valve lever to the "O" (open)

position. (see Figure 15).

3. Move engine run lever to RUN posi-

tion (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, page 11). Decompression lever will stay in this positon until you turn starting key.

II. Turn the starting key clockwise to

START positon (see Figure 18, page

11). 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.

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OWNER’S MANUAL

OPERATION

Continued

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 17). Decompression lever will stay in this position until you pull starter rope.

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:

snap back against engine. Return it gently. This will prevent damage to starter.

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

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

Decompression Lever

Do not let starter grip

HIGH ALTITUDE OPERATION

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

ADDING ELECTRICAL LOADS

IMPORTANT:

Make sure total wattage of all electrical 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:

switch in the 120 VOLT ONLY position if onlyu 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:

electrcal motors are misleading. They 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, pages 8 and 9.

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.

Keep full power selector

The wattage ratings for some

3. Push down engine stop lever (see Figure 19). 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 20).

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 19 - Pushing Down Engine Stop Lever

Figure 17 - Decompression Lever

Starting Key

OIL

CHARGE

OFF

Figure 18 - Starting Key

107359

DISCONNECTING ELECTRICAL 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.

Fuel Valve Lever

Figure 20 - Fuel Valve Lever In “S” Position

PORTABLE DIESEL GENERATOR

MAINTENANCE AND REPAIRS

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

TROUBLESHOOTING

Note:

For additional help, visit DESA

International’s technical service web site at www.desatech.com.

Note:

See engine owner’s manual for en-

gine troubleshooting.

CAUTION: Shut off generator

before performing maintenance.

IMPORTANT:

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: Only a qualified electrical service person should service

and repair generator. Use only factory approved replacement parts.

Keep generator level when

STORAGE

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:

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.

Keep generator level while

OBSERVED PROBLEM

No voltage when starting generator with no electrical load

Voltage is less than normal voltage with no electrical load

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

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

1. Engine speed too high

1. Defective rotor diode

2. Electrical load too high

3. Engine not running properly

www.desatech.com

REMEDY

1. Replace capacitor

2. Check resistance of coils (see Electri- cal Component Specifications, page 13)

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 Electri- cal Component Specifications, page 13)

5. Replace capacitor

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

107359

OWNER’S MANUAL

ELECTRICAL COMPONENT SPECIFICATIONS

Resistance in Ohms

Stator Stator Rotor Rotor Capacitor,

Main Auxiliary Primary Secondary MFD Diodes (2)

∆

Model Winding * Winding

MGY5000C 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.

WIRING DIAGRAMS

Winding † Winding † 450 Volt 800 Volt

120/240V 20A

Receptacle

White

Black

Green

Black

Green

Red

Black

Red

Black

White

Main

Windings

Red

Black

White

Hour Meter

Full Pwr Selector

Switch

Yellow

Red

Rotor

Diode

Capacitor

White

Green/Yellow

Circuit

Breaker

25A

Circuit

Breaker

25A

Yellow

Black

Red

White

Figure 21 - Alternator Wiring Diargram

Charge

Coil

Green/White

Charge

Regulator

White

Fuse

White Red

Red

Bridge

Black

Green Yellow White

Starter Motor/

Solenoid

Battery

Red

Red White

Black

Relay

Low Oil

Pressure Lamp

2 3 4 1

Shutdown

Red

Green

Solenoid

White

Green Yellow White

Red

Yellow

Oil Pressure Switch

Black

White 120V, 15A Receptacle

Duplex

Auxiliary

Phase

Diode

Black

Key

Switch

White

120V, 15A

Receptacle

Red

Stator

hite

Brown

GFCI

HOT

LINE

Green

Black

Charge

Lamp

Green

HITE W

White

110/120V

120V, 30A Receptacle

Green

Stator

220/240V

110/120V

Black

Circuit

Breaker

20A

Circuit

Breaker

20A

Figure 22 - Engine Wiring Diagram

107359

Continued

PORTABLE DIESEL GENERATOR

TECHNICAL SERVICE

You may have further questions about assembling, operating, or maintaining this product. If so, you can visit our Technical Service web site at

www.desatech.com or

contact our Technical Service Department at 1-800-858-8501 (English Only). You may also write to:

DESA Power Tools™ P.O. Box 90004 Bowling Green, KY 42102-9004 ATTN: Technical Service Power Tools

When contacting DESA Power Tools™, have ready

•Your Name

•Your Address

•Your Phone Number

• Model Number of Product

•Date of Purchase (Include copy of receipt for written requests).

SERVICING THE ENGINE

For Yanmar engine replacement parts, contact Parts Company of America at 1-800323-0620. 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.

REPLACEMENT PARTS AND ACCESSORIES

For original replacement parts and accessories, contact your nearest Authorized Dealer or Authorized Service Center for this product. If they can not supply the part or accessory, contact your nearest Parts Central listed on pages 14 and 15. Each Authorized Dealer, Authorized Service Center, and Parts Central is independently owned and operated.

See pages 15 through 18 for an Illustrated Parts List.

If you need additional referral information, contact our Technical Service Department (see Technical Service, page 14).

In Canada call 1-800-561-3372 for parts information.

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.

REPAIR SERVICE

Note:

Only use original replacement parts. This will protect your warranty coverage for parts replaced under warranty.

Each Authorized Service Center is independently owned and operated.

WARRANTY SERVICE

If product requires warranty service, return it to nearest Authorized Service Center. You must show proof of purchase. If faulty materials or workmanship caused damage, we will repair or replace product without charge.

Note:

Normal wear, misuse, abuse, neglect, or accidental damage is not covered under warranty.

NON-WARRANTY SERVICE

If product requires service, return it to nearest Authorized Service Center. Repairs will be billed to you at regular repair list prices.

For additional Service Center or warranty information, call 1-800-858-8501 or visit our Technical Service web site at

www.desatech.com.

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.

Tool & Equipment

5 Manila Drive Hamden, CT 06514-0322 203-248-7553 1-800-397-7553

Grainger Parts Operations

1657 Shermer Road Northbrook, IL 60062-5362 708-498-5900 1-800-323-0620 www.grainger.com

Portable Heater Parts

342 North County Road 400 East Valparaiso, IN 46383-9704 219-462-7441 1-800-362-6951 www.portableheaterparts.com sales@portableheaterparts.com techservice@portableheaterparts.com

FBD

1349 Adams Street Bowling Green, KY 42103-3414 270-846-1199 1-800-654-8534 franktalk@aol.com

Master Part Distributors

1251 Mound Avenue NW Grand Rapids, MI 49504-2672 616-791-0505 1-800-446-1446 www.masterparts.net

Bowden Electric Motor Service

1681 S. Wesleyan Blvd. Rocky Mount, NC 27803 252-446-4203

East Coast Energy

10 East Route 36 West Long Branch, NJ 07764-1501 1-800-755-8809

Laportes

2444 N 5th Street Hartsville, SC 29550-7704 843-332-0191

MTA Distributors

555 Hickory Hills Blvd. Nashville, TN 37189-9244 615-299-8777 1-800-264-0225

Industrial Hardware

4109 Bainbridge Blvd. Chesapeake, VA 23324-1403 804-543-2232 1-800-788-0008 catatem@erols.com

Mills Lawn and Garden

928 Commonwealth Place Virginia Beach, VA 23464 757-361-9293 www.mills-parts.com

Tuco Industrial Products

5223 180th Street SW Suite 4A-1 Lynnwood, WA 98037-4506 425-743-9533 1-800-735-1268 www.tucoheat.com

107359

ILLUSTRATED

OWNER’S MANUAL

PARTS LIST

ALTERNATOR ASSEMBLY

This list contains replaceable parts used in your generator. When ordering parts, follow the instructions listed under Replace- ment Parts on page 14- of this manual.

KEY PART

NO. NUMBER DESCRIPTION QTY.

099723-02 Alternator Assembly 1 1 099844-01 End Cover 1 2 099701-01 Screw, M5 x 10mm 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.

107359

PORTABLE DIESEL GENERATOR

ILLUSTRATED PARTS LIST

FUEL TANK AND ROLL CAGE

This list contains replaceable parts used in your generator. When ordering parts, follow the instructions listed under Replace- ment Parts on page 14 of this manual.

9 8

2 3

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 103880-01 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 10 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" 4 14 WLE-5 Washer, 5/16" 3 15 103289-01 Shock Mount 1

KEY PART

NO. NUMBER DESCRIPTION QTY.

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

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

(Positive) 1

099873-02 Battery Cable

(Negative) 1

099954-01 Spark Arrestor 1

107359

ILLUSTRATED

OWNER’S MANUAL

PARTS LIST

CONTROL PANEL

This list contains replaceable parts used in your generator. When ordering parts, follow the instructions listed under Replace- ment Parts on page 14 of this manual.

120 V

LTS

ENM

00000005

FULL POWER

120 ONLY

SELECTOR

RESET TEST

120/240V

120/240 V

LTS

ESE

KEY PART NO. NUMBER DESCRIPTION QTY.

1 103349-02 Control Panel 1 2 22616009 Circuit Breaker, 20 Amp * 2 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 101350-01 Hour Meter 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 15 099836-01 120V, 15A Duplex Receptacle * 1 † 103348-02 Control Panel Assembly 1

PARTS AVAILABLE - NOT SHOWN

100177-07 Panel Schematic Decal 1

107359

* Includes fastening hardware † Includes reference numbers 1 through 15

PORTABLE DIESEL GENERATOR

ILLUSTRATED PARTS LIST

SWITCH CONTROL BOX

This list contains replaceable parts used in your generator. When ordering parts, follow the instructions listed under Replace- ment Parts on page 14 of this manual.

KEY PART NO. NUMBER DESCRIPTION QTY.

1 101037-01 Switch control box 1 2 22721000 Low oil light 1 3 099936-01 Key switch, lamp, and

harness assembly 1 4 101039-01 1/4-28 Keps Nut 4 5 099760-01 Strain relief bushing 1 6 101040-01 1/4-20 x 5/8"

Hex Head Sems 2 7 26498000 Relay 1 8 NTF-3C #10-32 Hex locknut 1 9 RN12000100 Adhesive-backed

PVC foam 1 10 * Connector 1 11 * #6-32 x 1/2"

Hex tapping screw 1 12 * #6 Internal-tooth

lockwasher 5

KEY PART NO. NUMBER DESCRIPTION QTY.

13 26509000 Full bridge 1 14 26002006 #8-32 x 3/8" Screw 4 15 15020000 Grommet 1 16 WP-3C #10 Flat washer 1 17 26499000 #10-32 x 3/4"

Hex-head screw 1 18 26490000 Solenoid 1 19 26494000 M4 x 8 Hex-head screw 2 20 26492000 M3 x 8 Hex-head screw 4 21 101038-01 Control Box Cover 1 22 101036-01 Cable 1 23 101035-01 Conduit 1 † 101103-01 Switch Control Box

Assembly 1

PARTS AVAILABLE - NOT SHOWN

101042-01 Wire Nut 1

* Available from your local hardware store † Includes reference numbers 1 through 23

107359

OWNER’S MANUAL

NOTES

_______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________ _______________________________________________________________________________________________

107359

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 five-year limited warranty below covers all non-engine parts of this generator including the alternator. Honda warrants the engine.

See engine owner’s manual for engine warranty information.

FIVE-YEAR LIMITED WARRANTY

PORTABLE GENERATORS

DESA Power Tools™ warrants each alternator, generator, or electric product of its manufacture, to be free from defects in material and workmanship for five 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 Power Tools™ 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 five years from the date of first purchase, and DESA Power Tools’™ liability is hereby limited to the purchase price of the product and DESA Power Tools™ 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.

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

www.desatech.com

107359-01

REV. C

06/04

Master Lock MGY5000C User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual