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Master Lock MGY5000 manual

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Table of contents for the manual

  • Page 1

    POR T ABLE DIESEL GENER A T OR OWNER’S OPERA TION AND INST ALLA TION MANUAL R 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. Generator Model: MGY5000 RUN STOP EF RESET TEST RESET 120 VOLTS FULL POWER SELECTOR 120 ONLY 120[...]

  • Page 2

    2 SECTION PAGE Safety Information ........................................................................... 3 Product Identification ...................................................................... 6 General Information ........................................................................ 7 Specifications ................................[...]

  • Page 3

    3 SAFETY INFORMA TION ! WARNING ICON G 001 W ARNINGS 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[...]

  • Page 4

    4 SAFETY INFORMA TION Continued 2. ! WARNING Guard against fire hazard. Keep operation area well-vented. Keep generator at least three feet away from any object. Do not place flam- mable 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. •[...]

  • Page 5

    5 SAFETY INFORMA TION Continued 8. ! WARNING 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. 9. ! [...]

  • Page 6

    6 EF RUN STOP EF RESET TEST RESET 120 VOLTS FULL POWER SELECTOR 120 ONLY 120 240V 120/240 VOLTS RESET RESET PRODUCT IDENTIFICA TION Figure 1 - Portable Generator Control Panel Roll Cage Alternator Engine Run Lever Electric Start Switch Fuel Valve (under fuel tank) Engine Stop Lever Circuit Breaker Decompression Lever Starter Grip Fuel Gage Fuel Cap[...]

  • Page 7

    7 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 [...]

  • Page 8

    8 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. VENTI[...]

  • Page 9

    9 CHARGE OFF OIL Battery Discharge Lamp Oil Alert Lamp Figure 2 - Battery Discharge Lamp and Oil Alert Lamp Location Continued GENERA TOR FEA TURES Continued FULL POWER SELECTOR SWITCH The full power selector switch is on the control panel. The switch has two posi- tions: 120 VOLT ONLY, and 120/240 VOLT. 120 VOLT ONLY: This position sends full powe[...]

  • Page 10

    10 GENERA TOR FEA TURES 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. [...]

  • Page 11

    11 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 hi[...]

  • Page 12

    12 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 in[...]

  • Page 13

    13 FUEL WARNING ICON G 001 W ARNING 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[...]

  • Page 14

    14 WARNING ICON G 001 CAUTION If you remove battery, insulate the red, positive (+) battery cable terminal. Insulate with electrical tape. Exposed terminal may spark when generator runs. Starter Solenoid Figure 8 - Connecting Red, Positive (+) Battery Cable to Starter Solenoid on Engine BA TTER Y Continued IMPORTANT: Make sure battery connections a[...]

  • Page 15

    15 BA TTER Y Continued Nut Battery Battery Mounting Bracket Hook Bolt Red, Positive Cable From Starter Solenoid Black, Negative Cable From Engine Block Figure 10 - Battery Hold-Down System Figure 11 - Connecting Positive and Negative Cables to Battery MOUNTING BATTERY TO GENERATOR 1. Secure battery to generator by battery hold-down system. This sys[...]

  • Page 16

    16 GENERA TOR GROUNDING WARNING ICON G 001 CAUTION You must properl y 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 grou[...]

  • Page 17

    17 EXTENSION CORDS Only use grounded extension cords. Be sure to use extension cord with proper wire gauge size. See chart below. Ampere AWG for Length of Cord in Feet Load 50' 100' 150' 21 8 1 8 1 8 31 8 1 8 1 8 41 6 1 6 1 6 51 6 1 6 1 6 61 6 1 6 1 4 81 6 1 4 1 2 10 16 14 12 12 14 14 12 14 14 12 10 16 12 12 10 20 10 10 8 Recommended[...]

  • Page 18

    18 DETERMINING ELECTRICAL LOAD FOR GENERA TOR 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 w[...]

  • Page 19

    19 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. OPERA TION WARNING ICON G 001 DANGER Use only in well-vented areas. Make sure area h[...]

  • Page 20

    20 OPERA TION 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 w G YX Ground X (Hot) W (Neutral) Y (Hot) Ground (Green) L14-20P Plug 120V 120V Neutral 120/240 Volt 20 Amp Figu[...]

  • Page 21

    21 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 genera- tor near standing water and snow. Make sure area is well-vented. OPERA TION Continued Note: If oil level is too low, oil alert system will keep engine from starting (see Oil [...]

  • Page 22

    22 OPERA TION Continued O S Fuel Valve Lever Figure 15 - Fuel Valve Lever In “O” (open) Position RUN STOP Engine Run Lever 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 ke[...]

  • Page 23

    23 OIL OIL 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 ICON G 001 W ARNING Never use gasoline, paint thinner, or any other flammable liquid as a starting aid. An explosion may occur. W[...]

  • Page 24

    24 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: Do not let starter grip snap back against engine. Return it gently. This will prevent damage [...]

  • Page 25

    25 RUN STOP Engine Stop Lever Figure 21 - Pushing Down Engine Stop Lever Figure 22 - Fuel Valve Lever In “S” Position O S Fuel Valve Lever 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 th[...]

  • Page 26

    26 MAINTENANCE AND REP AIRS WARNING ICON G 001 W ARNING Only a qualified electrical service person should service and repair the alternator on this generator. Use only factory approved replacement parts. WARNING ICON G 001 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[...]

  • Page 27

    27 TROUBLE- SHOOTING Note: See engine owner’s manual for engine troubleshooting. WARNING ICON G 001 W ARNING Only a qualified electrical service person should service and repair generator. Use only factory approved replacement parts. POSSIBLE CAUSE 1. Defective capacitor 2. Winding short circuit or loose connections 3. Defective rotor diode 4. Lo[...]

  • Page 28

    28 Figure 24 - Engine Wiring Diagram WIRING DIAGRAMS Figure 23 - Alternator Wiring Diagram Starter Motor/ Solenoid White Red Battery Red Black + - Charge Regulator White Yellow Green 2 3 4 1 Green Green White Red Yellow Key Switch Charge Lamp Black Green/White Green/White Charge Coil Bridge Red Red White Low Oil Pressure Lamp 30 86 87 85 Green/Whit[...]

  • Page 29

    29 TECHNICAL SER VICE You may have further questions about installation, operation, or troubleshooting. If so, contact DESA International’s Technical Service Department at 1-800-323- 5190. SER VICING THE ENGINE For Yanmar engine replacement parts, contact Parts Company of America at 1- 800-323-0620. Yanmar engine servicing should be handled by yo[...]

  • Page 30

    30 1 6 2 10 12 15 16 17 13 14 18 19 20 21 22 9 24 23 3 9 8 4 7 5 11 25 ILLUSTRA TED P ARTS 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 G[...]

  • Page 31

    31 ILLUSTRA TED P ARTS LIST Fuel Tank and Roll Cage 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[...]

  • Page 32

    32 ILLUSTRA TED P ARTS LIST Control Panel RESET FULL POWER SELECTOR 120/240 VOLTS RESET RESET 1 2 3 4 5 7 6 6 9 10 11 12 12 13 120 ONLY 120 240V 120 VOLTS 8 RESET TEST 14 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 Duple[...]

  • Page 33

    33 ILLUSTRA TED P ARTS LIST Switch Control Box 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 R[...]

  • Page 34

    34 P ARTS 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[...]

  • Page 35

    35 NOTES[...]

  • Page 36

    36 KEEP THIS WARRANTY W ARRANTY INFORMA TION 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 pr[...]